Competency includes sufficient knowledge of: Coal Proximate and ultimate analysis classification of coal for metallurgical coke Coke coal carbonisation technical aspects of coke making coke model, coke manufacture by-product ovens sequence of battery operations coke properties - caking and swelling quality control tests for coke (crucible swelling number and Gray-king coke type) coke strength and abrasion, resistance CRS - reactivity tests. Other Fuels blast furnace gas - uses coke oven gas - uses fuel oil - injection of auxiliary fuels tar and pitch IronOre mineralogical characteristics sources of iron, locations of ore chemical analysis - ore quality desirable, unwanted impurities desirable properties for iron making mining/preliminary treatment (ore beneficiation) ore handling blending/stacking (chevron/step stacking) essential characteristics of iron ore - reducibility/strength size distribution - lump ore - direction charging fine ore - need for agglomeration for good permeability testing and quality control of iron ores for iron making resistance to fines generation drying handling and charging resistance to decrepitation low temperature reduced degradation (Nagoyal test) height temperature reducibility (Gakushin test) softening under load cohesive zone of (BF) Ore Agglomeration Need for agglomeration, sources of fines, aims for agglomeration Pelletising use of pelletising; size and quality of ore pelletising process quality control needs for pellets abrasion index, RDI index Sintering sintering process proportioning of raw materials size of ores, blending, moisture limestone and coke mixing and granulation sinter characteristics, sinter quality size, strength, reducibility chemistry (basicity ratio) quality control tests for sinter sieving and sizing sinter tumble test (abrasion test) low temperature reduction, degradation (reduction degradation index - RDI), high temperature reducibility Miscellaneous Raw Materials Fluxes: Limestone, fluorspar, quartzite manganese ore, air/tonnage oxygen, water Iron Blast Furnace Operations general description and function of blast furnace including charged materials blast furnace terminology blast furnace chemistry (reduction chemistry and gaseous v's solid reduction) thermodynamics of iron making (physio chemical principles) free energy charges; Ellingham diagram/oxygen potential equilibrium/equilibrium constant/activity dependence of coke/oxygen reaction and gas composition Blast furnace slags slag/metal reactions slag formation reactions Construction and Design of Blast Furnaces furnace construction/furnace profile layout and function of processing units associated with the blast furnace charging and distribution ore blending, raw material bins raw material control and charges furnace filling use of moveable armour refractories and cooling systems choice of refectory materials for furnace lining method of cooling/under hearth cooling/stave cooling campaign life determinants - link between refractories and cooling system blower stations: hot blast stoves, tuyeres gas cleaning equipment , dust extraction cast house layout slag/metal flow-slag disposal blast furnace sensors computer control sensors and interpretation human eye tuyere/casting condition thermocouples hot metal stoves brickwork tip temperature probes pressure tapping level detectors flow meters flow rate of gases/hot blast chemical analysis composition of metal slag and waste gases Principles of Iron Making furnace filling mechanism of charging and of distribution segregation effects blast furnace zones of operations physical movement through the furnace counter current process solids/gas and temperature profile five internal zones lumpy/granular zone, cohesive zone, active coke zone raceway hearth and deadman lumpy/granular zone-zone formation cohesive zone-zone formation active coke zone-zone formation importance of coke properties zone chemistry - effects of metal, coke, alkalis and fluxes/slag. raceway physical structure, raceway model-factor affecting shape-blast parameters combustion in raceway, importance of coke additives to replace coke to improve control and production. hearth and deadmen-zone formation (deadman boundary residence time of coke) gas/liquid flow, liquid levels floating levels, floating of coke bed liquid permeability effect of casting rate fluidity of slag and metal liquid flow: effect on lining wear. hot metal and slag chemistry hot metal - optimisation of hot metal composition control of carbon, silicon, manganese, sulphur, phoporus slag - mechanism of slag formation optimisation of slag chemistry requirements of a good slag -melting point, basicity, viscosity ability to remove unwanted materials, (de sulphurising power) slag volume requirements for effective and efficient operation importance of raw material quality and quantities burden distribution , tuyere injectants, fuel rate elimination of irregularities Post Iron making Practices reasons for post iron making productivity control of unwanted elements control of hot metal, composition for BOS steelmaking and balance of exothermic reactions de sulphurising, dephosphorisation, desiliconising lime, magnesium, aluminium importance of injectants and slag formers, significance of slag partitioning |