Determination of the Cohesive Zone of the Blast Furnace

Carlos R. Gmez Fuentealba

Siderar Senior Process Engineer
Ral C. Ametrano
Siderar Manager Blast Furnace Department
Pedro R. Etchevarne
Siderar Process Engineer
Jos L. Zubimendi
Siderar Assistant Manager Blast Furnace Department
Siderar SACI, P.O. Box 801, 2900 San Nicols, Argentina
Tel.:54-3461-438611
Fax: 54-3461-438619
apagof@siderar.com; apaamt@siderar.com
apaetp@siderar.com; apajzu@siderar.com
Key words: Cohesive zone, Softening point, Melting point
ABSTRACT
After the dissections of the blast furnace (BF) the existence of a cohesive zone (CZ) became apparent,1 where the layers of ore are
softened and fused, loosing there lumpy state and becoming impermeable to the gases. The formation of the CZ has been studied
deeply, and therefore the effects on the productivity, fuel rate, and on the wall wearing are well known. The challenge today is to
determine its position in the BF when it is in operation; therefore many computer generated models and penetrating burden probes
have been developed. However such resources are not always economically justified, so this work is about determining the
position of the CZ with the available instrumentation.
INTRODUCTION
The objective of this work is to obtain the CZ position, on line in the control room, with a degree of accuracy according to the
available instrumentation.
The instrumentation of Siderar BF N 2 used for the purpose of this work is the following:
An above burden probe (Figure 1) with 24 sample points for measuring gas composition and temperature
A pressure taps measurement of seven levels plus the top and the bustle main (Figure 2)
Heat losses (Figure 3)
Bell less top with a circular distribution system and a volumetric model (Figure 4)
The general instrumentation commonly used
As the softening point and melting point of the material used in the burden were needed, these were therefore tested.
A mass and energy balance is done by dividing the BF into four regions to determine the temperatures of the inlet and outlet of the
burden and gases in the cohesive zone. The BF is then divided into 24 sections (Figure 5), each one associated with one sample
point of the above burden probe at the top, and thus, 24 columns are formed (Figure 6). They start in the CZ up to the top. These
columns are made of lumpy material, where equations that govern the fluid dynamic, mass and heat transfer are well known. The
conditions of the material and the gas at the top, as at the other end in the CZ, are already known. The information which is
required is the mass flow of the gas that is obtained by a mass and energy balance for each column. Therefore, by iteration from
the top to the softening point temperature, the 24 points of the cohesive zone are determined (Figures 8 and 9).

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THE MAIN FEATURES OF THE BLAST FURNACE FOR THE PURPOSE OF THIS WORK
Above Burden Probes
There are four above-burden probes, each containing six sample points, which are located 0.80 m above the stock line forming a
cross. They are named South, North, West and East (Figure 1). The sample points are numbered from the center to the wall by
1,2,3,4,5 and 6 so each sample point can be identified by that number and by the probe they belong to. For example: a 4E means
that it is sample point 4 of the East burden probe. In each position of a sample point, the temperature and gas composition (% H2,
% CO and CO2) is measured. There is also a global gas measurement of temperature in a sample point at the uptake of the BF and
gas global composition after the gas cleaning.

Figure 1 Above burden probe

Pressure Taps
The pressure taps consist of four rows of 7 measurement points each, located against the wall in the same vertical planes that
contain one of top burden probes. Each row is named North, South, West and East. At 7 different heights of the BF on a horizontal
plane there are, therefore, four measurement points. In figure N 2 a representation of pressure from the bustle main to the top of
the BF can be seen, in cylindrical coordinates.
Figure 2 Pressure taps
measurements
The Heat Losses
The heat losses are
measured in 8 segments of
the furnace over 4 vertical
sections

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Figure 3 Heat losses

Burden distribution
For the distribution of the different material into the BF there is bell less top system aided by a volumetric model that allows a
profile to be obtained of the percentage of coke and minerals along the radio throat of the BF.

Figure 4 Volumetric distribution of the burden

Gener
al
Instru
menta
tion
Also
availa
ble is
the
necess
ary
basic
instru
menta
tion to
deter
mine
the
input
and
output
for
calculating the mass and energy balance such as weights, burden level, temperatures, flow, composition, pressure, moisture, etc.,
which are well known.

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THE SOFTENING AND MELTING POINTS OF MATERIALS

As data needed the softening point and melting point of the material used in the burden they were tested individually and mixed in
the same proportions that are charged in the BF. Notably there are behaviors changes of the minerals when they are mixed
compared with when they are alone. (Table I and II)
Table I Softening point of the materials used

1550
1500
1450
1400
1350
1300
1250
1200
32S+28P+22C+18M

32S+28P+22C+18S

32S+28P+22C+18F

32S+28P+22C+18U

Pellet B

Pellet CO

Pellet N

Pellet CC

Pellet SG

Pellet S

Sinter Ib:2.20
MgO:1.30

Sinter Ib:2.20
MgO:1.70

Sinter Ib:2.20 MgO:

2.34

Sinter Ib:1.79
MgO:1.61

Sponge Iron

Sinter Ib:2.35
MgO:2.16

Lump U

Lump C

Lump F

Lump CA

Lump SC

Lump S

Lump M

1150

Table II Range temperature of the Cohesive Zone of the used material

300
250
200
150
100
50

32S+28P+22C+18M

32S+28P+22C+18S

32S+28P+22C+18F

32S+28P+22C+18U

Pellet B

Pellet CO

Pellet N

Pellet CC

Pellet SG

Pellet S

Sinter Ib:2.20
MgO:1.30

Sinter Ib:2.20
MgO:1.70

Sinter Ib:2.20 MgO:

2.34

Sinter Ib:1.79
MgO:1.61

Sinter Ib:2.35
MgO:2.16

Sponge Iron

Lump U

Lump C

Lump F

Lump CA

Lump SC

Lump S

Lump M

MODELS FUNDAMENTALS
Considering the stock line as a horizontal section which is divided into 24 portions (Figure 5), each portion of area is related to a
burden probe sample point that is located at medium radio in its axis of symmetry. Another consideration (or simplification) is
that each charge (a layer of coke and mineral) has the same volume until it reaches the CZ. The charge is divided into 24 cells as
the result of multiplying the area portions by the charge thickness. A third consideration is that the volume of the 24 cells will be
constant in their journey from the top to the CZ. What will vary is the area and the thickness. On the other hand, the portions of

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area will conserve their shape and proportion in any cross horizontal section. In each cell there is a volume of coke and mineral
which remains constant. In accordance to this, both volumes are also constant although they lose mass due to the fact that their
porosity increases.

Above burden probes sample point related to each cell

and its burden profile

ral
Mine

Mine
ral

3 4

Coke

Coke

Thickness Charge

Cells East

Cells West

Cells North

Cells South
Figure 5 Scheme of the above burden probe related to each cell and burden profile
If we number the charge at the top forming the stock line as number one and the last charge the one at the CZ, we can now
identify any cell inside the BF by the burden probe sample point and the number of charge. For example: 1 E 23er, cell beneath
burden probe East, sample point one (center) at the level of the charge 23er. The computer, according to the volume of 23 charges
from the top, determines at which level from the top the twenty third charge is located.
Now if all cells are related to the same sample point of a burden probe, there is then the formation of a column, (Figure 6), and
there will be as many columns as sample points, which is 24.
From the base to the top, the columns of lumpy material start at the CZ and end up at the stock line. It is assumed that the mass of
gases that enter each column at its base will remain in that column up to the top, which means that there is considered to be no
radial flow.

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Column form by cells related to the same sample

point of the above burden probe
Temperature and composition
of the gas given by sample
point of the above burden
probe

Masses of mineral and coke

known by the burden
distribution model
Granular coke
Impervious mineral
Entered gas temperature and
composition calculated by the
global heat and mass balance

Figure 6 A sections consider along the total height form a column.

Therefore the conditions of the input material, the temperature, and the pressure and composition of the outlet gases for each
column, are already known. What is not known is the amount and the enter condition of gas that circulates per column.
According to what has been published about the dissection made in the BF the CZ, it is to be associated with an isotherm which
depends on the softening point of minerals in the burden. In the case of Siderar the pellet, sinter and lump ore are mixed and
distributed along the radio of the throat in equal proportions, so that they behave as if they were only one mineral with the same
softening point. If the CZ starts in an isotherm it is assumed that the reaction coordinate (RC degree of advance of a chemical
reaction) is the same for all the layers of minerals that reach the CZ. In other words, they have the some proportions of Fe and
FeO.
Another assumption in the lumpy zone is that the rate controlling factor is the heat transfer and so the RC is a function of the
temperature that reaches the minerals.
To fix the gas conditions and the mineral at the starting fusion we divided the BF into four thermal regions and applied a mass and
heat balance to each.
1

From the top to the thermal reserve zone 900 C (Upper Zone).

From the thermal reserve zone to the starting of the CZ (Above the CZ).

CZ (Cohesive Zone).

From CZ to the hearth (Lower Zone).

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Stock Line

Isotherm 900 C

Cohesive Zone

Figure 7 Energy balance

Below the CZ it is considered that there is no CO2 or H2O because of the high temperatures and the solid medium of coke, so the
compositions of the gases leaving this region consist of N2, CO and H2. The balances are fixed by three parameters; the
percentage of the direct reduction below the CZ, and the leaving and entrance temperatures of the gases in the CZ. Once this
global balance of energy is solved we have all the conditions needed for the gases and the layers of minerals at the softening point
or the starting of the CZ. Now a heat and mass balance is possible for each column, with the determination of the gas for each
column that must mesh with the global balance.
We now have the necessary data to feed the equations of heat, momentum and mass transfer between lumpy columns and gases
that pass through them. At this point the specific heat, thermal conductivity and viscosity of the gases as a function of the
temperature and composition are also known. To complete the solid packed bed made of layers of coke and mineral we assume
that the reduction of the iron oxides RC was also a function of the temperature that the minerals reach. Therefore, the thermal
properties that depend on the composition are known, as well as the heat of the chemical reactions.
Considering the conditions of our BF in which the gas leaving the CZ upwards has 20 % of H2, for the kinetics calculation the rate
of chemical reactions is not the controlling step for a productivity of 3 t/day/m3 of WV. What we consider as the controlling
factor for the global rate is the heat transfer rate, so the temperature is associated with the RC. This last process, therefore, is what
defines the position of the CZ, when the mineral reaches the temperature of the softening point.
There is now the necessary data to feed the following equations:2

P12 - P22 = F [R,G 2T , M , fm , L ,( 1 )3 n /( 3S n 3 Dp )]

j H = 0.61 . Re-0.41*
hloc = jH .Cpb .G (
Where:
p1: Upstream absolute pressure
a: Specific surface per packed volume
Dp: Average particle diameter
Re: Reynolds number

Cp

).2 / 3

p2: Downstream absolute pressure

: Void fraction of the lumpy zone
G: Gas mass velocity
R: Universal gas constant

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: Gas thermal conductivity

M: Gas molecular weight
: Gas viscosity
hloc : Local coefficient of forced convection
jH : Chilton-Colburn factor for the heat transfer

Cpb: specific heat of the bulk gas

T: Absolute temperature
fm: Modified friction factor
(): Film conditions
s: Shape factor

q = h loc .a.S .L.(TS - Tb )

This last equation represents the transfer of heat from the gas to a granulated burden through a force convection process, where the
driving force is the difference of temperature magnified by a (specific surface per packed volume),3 of which the value depends
on the properties of the materials that make up the packed bed. The calculation for our particular case should be pointed out: The
gas transfer is three times more heat per layer of mineral than per layer of coke. The reason for this is that the coefficients , s ,
Dp give a specific surface three times greater for the mineral than for the coke. Although the heat capacity of the coke is three
times less than that of the mineral, in the end the increase of temperatures is similar.
With these equations, iteration is done from the top layers to the bottom layers by taking the temperature as a parameter which is a
result for each cell of the heat transfer, the variation of enthalpies of the chemical reactions, the humidity of the burden, specific
heat and, for the external columns, the heat loss.
Besides the heat transfer by convection (the main factor) the heat is also transferred by conduction and radiation layer by layer, so
there is a coefficient that is adjusted in such a way so that integration of the heat transfer to the columns coincides with the global
balance.
The steps for reaching this calculation are the following
:
1- Global balance of mass and energy.
2- Determination of percentage of Direct Reduction below the CZ and temperatures of gas and mineral that enters and leaves it.
3- Determination of the gas composition that enters or leaves the CZ (no chemical reaction within it).
4- Conditions and properties of the minerals on basis of the reaction coordinate from oxides to Fe.
5- Heat and mass balance for each of the 24 columns.
6- Calculation per layer of heat transfer from the top downwards until it reaches the melting point for that column.
Therefore there are 24 points at a calculated distance from stock line. These points belong to CZ and the results are shown in the
way that they appear on the screens of the control room (Figures 8 and 9).

Figure 8
Position of CZ reducing blast

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Figure 9
Position CZ increasing production

AISTech 2004 Proceedings - Volume I

These two images are obtained by integrating two hours of data. The time the computer takes to form them is thirty seconds.
SUMMARY
We obtain an image, on line of the CZ position on the screen of control room with a degree of accuracy according to the available
instrumentation. The time to build up the image is thirty seconds, and integrates two hours of previous data. It is necessary for the
BF to remain stable during that period of time.
The information about the shape of CZ influences the productivity, the fuel rate, and the wall wearing, and can also prevent
tuyeres tipping. Additional information is obtained as a profile of the burden temperature at different levels, which allows us to
simulate a test of materials as if they were in the BF. The weight of the columns of lumpy material are also obtained, which are
useful for the balance of forces in the hearth to determine floating dead man and to solve high temperatures and wearing in the
hearth.
Future improvements for this model include the possibility of giving information of the CZ in no steady state, which we believe is
related to the treatment and elaboration of data.
ACKNOWLEDGEMENTS
We are thankful to Claudio Partemio who allowed us to use the table of his work Softening point of raw materials for the BF
and to Eduardo Oliva who made the computational programs and design the screens.
REFERENCES
1.
2.
3.

Omori, Y., Ed., Dissection of Quenched Blast Furnaces, Blast Furnace Phenomena and Modeling, Committee on
Reaction within Blast Furnace, Joint Society on Iron and Steel Basic Research. The Iron and Steel Institute of Japan,
Elsevier Applied Science, 1987, London, pp. 3-31
Perry, R.,H.,Chilton, C., H.,Fluid and Particle Dynamics, Perrys Chemical Engineer Handbook, McGraw-Hill Co.
Fifth Edition, pp. 52-53
Bird, R., B., Stewart, W., E., Lightfoot, E., N. Transporte de Interface en Sistemas no Isotermicos, Transport
Phenomena, John Wiley & Sons, Inc., New York , Editorial Reverte S.A. 1964, pp. 24-25

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