The Performance of LKAB’s Experimental Blast Furnace in Modern Ironmaking
Guangqing Zuo, Nicklas Eklund and Peter Sikström
LKAB, Box 952, 97128, Luleå, Sweden
Phone - +4692038000
E-mail: [email protected]
Key words: Blast furnace, LKAB, Pellet product, Ironmaking, EBF
Introduction
Luossavaara-Kiirunavaara AB – LKAB is an international high-tech minerals group, one of the world’s leading producers of upgraded
iron ore products for the steel industry and a growing supplier of industrial minerals products to other sectors. LKAB is wholly owned
by the Swedish state and a public limited company with headquarter in Luleå, Sweden. LKAB’s mission is, based on the Swedish ore
field, to manufacture and deliver upgraded iron ore products and services that create added value for its customers.
Most of the iron ore products are purchased by European steelworks. Other important customers are from Kina, Southeast Asia, North
Africa and Middle East. Industrial minerals are offered mainly to Europe but also to growing markets in Asia and the USA. Other
closely related products and services that are based on LKAB’s know-how and support the main business can also be included in the
company’s operations.
As the No. 1 iron ore producer in Europe which produces over 90% of iron ore products of Europe, LKAB does not own a commercial
blast furnace for ironmaking. Iron ore pellet product development was conducted directly from laboratory tests to full scale trials at
customer’s production furnace at LKAB before 1997, which had been demonstrated to be too risky for a production furnace and not to
be cost effective for product development. To accelerate the product development and to be able to always provide customers with
high-quality iron ore pellets, it was decided in 1996 to build an Experimental Blast Furnace - EBF for total 5 campaigns of about 6
weeks each and 2-campaign per year for developing iron ore pellet products between 1997 and 1999.
The EBF was erected and commissioned in 19971,2,3. During the first 5 campaigns, both LKAB’s internal product development
projects and external projects for optimising the blast furnace process were performed. It became very evident that the EBF is a
valuable tool not only for iron ore pellet product development but for other research and development of blast furnace ironmaking
technologies. As a result, the EBF was continued to use for exploring the blast furnace ironmaking technologies after 1999 and in the
mean time was consecutively improved for achieving expected trial results. To date 25 campaigns were conducted, including 3
campaigns for ULOCS Top Gas Recycled Blast Furnace, a few customer-orientated projects, ECSC and Jerkontoret’s projects. This
paper reports the performance of the EBF during the last 25 campaigns as well as its contributions to the developments of the modern
blast furnace ironmaking technologies.
LKAB’s Experimental Blast Furnace
Although the EBF as shown in Figure 1, is not as large as a commercial blast furnace in size, it is fully equipped as a commercial one,
or even better. The on-line measurements of the top gas composition of high accuracy as well as the gas temperature measurements in
two crossed diametrical directions can provide valuable information about the gas utilization and distributions inside the furnace. The
high pressure top up to 1.5 bar (gauge) makes it possible to operate the furnace at high blast volume without deteriorating process
performance. The advanced top charger developed by Z&J Technologies Gmbh gives great flexibility for adjusting the burden
distribution. ‘Live sampling’ during the operation through upper and lower shaft gas and burden probes, as well as the inclined burden
probe can provide more detailed ‘inside information’ for improved analysis of the furnace process. Tuyere optical cameras can help
the operator to enhance the thermal state control to some extent.
Technical Data of EBF
Working volume
Hearth diameter
Working height
3 Tuyeres
Max. top pressure
Throat diameter
Upper shaft
9 m³
1.4 m
6.0 m
54 mm
1.5 bar
1.0 m
-1 m
Lower shaft
Typical production figures
Inclined
-3.45 m
- 4.3 m
Blast volume
O2 in blast
Blast temp.
Fuel rate
Top pressure
Production
1700m³/h
25%
1250°C
530 kg/tHM
1.0 bar
36 t/d
Tuyere
-6 m
Figure 1. The experimental blast furnace
Figure 2 shows a schematic layout of the EBF plant. Four ferrous material bins, four slag former bins and one coke bin facilitate
greatly the test of different burden structure during a campaign. The charging system with skip car can serve the furnace well up to a
production rate of about 1.85 t/h. Advanced flexible injection system can admit multiple injections of pulverized coal together with
other solid pulverized materials, e.g. BOF slag and flue dust, simultaneously. Oil or reducing gas injection is also possible.
For heating up the cold blast two pebble heaters, functioning as hot stove, are used and are able to heat up the air from room
temperature to a temperature of about 1250°C. High oxygen enrichment ratio of up to 40% to blast was tested without any problem
during one campaign. Gas cleaning system with sampling function makes it very easy to take live flue dust and sludge samples for
further analysis when necessary.
Tapping system consists of a drilling machine for opening the tap hole and a mud gun for closing the tap hole. Sampling of hot metal
and slag as well as the measurement of the hot metal temperature during tapping are manually conducted. On-site chemical analysis of
hot metal and slag can provide quick thermal information to process engineers for controlling the furnace.
The EBF has been fully financed and is owned by LKAB, but situated on MEFOS premises. Design of campaign and process control
during each campaign are usually conducted by LKAB’s engineers and researchers, and sometimes jointly with partners if a trial was
for joint project. Dissection of the EBF after the campaign, sampling the burden materials during the excavation, as well as the further
evaluations of the probing and excavation samples are carried out independently by LKAB.
Figure 2. Schematic diagram of the LKAB’s Experimental Blast Furnace
EBF for Pellet Product Development and Quality Improvement
Development of the LKAB Acid Pellet1,2
Table I. LLKAB blast furnace pellets
wt%
KPBO
KPBA
Fe
66.6
67.1
SiO2
2.05
2.30
CaO
0.46
0.55
MgO
1.55
0.52
Al2O3
0.22
0.22
LKAB olivine pellets were introduced to the market in the early 1980s and
have been great successes in commercial blast furnaces with 100% olivine
pellet operations. For the first time better operating results were achieved with
pellets than with sinter in terms of productivity and fuel rate1. The appropriate
high softening and melting properties make it possible for blast furnaces with
100% pellet as ferrous burden to decrease the fuel consumption.
At the end of the last century demand on acid pellets
which could be used together with sinter in mixed burden
was quite strong. A new acid blast furnace pellet called
KPBA with higher iron content than previous acid pellet
and appropriate metallurgical properties was then
designed and tested in the laboratory. Thanks to the EBF,
KPBA was tested and optimized before successfully
introducing to customers. In the year of 2000, the new
product – KPBA with quartzite as main additive and
specially designed for blast furnace operation with sinter,
was launched. Table I presents the major chemical
compositions of one olivine pellet and KPBA.
Table II. Some comparisons between the EBF and an industrial BF
EBF (1.2 m)
Bremen No. 2 (12 m)
KPBO
KPBA
KPBO
KPBA
45.7
47.2
48.1
48.6
ηco
σ(ηco)
2.90
0.7
2.4
2.1
PV bosh
6.6
0.25
6.7
0.17
6.7
0.81
6.7
0.66
σ(PV bosh)
ηco: Top gas utilization ηco=CO2/(CO2+CO);
σ: standard deviation of ηco
PV bosh: permeability index of burden column
/
.
.
·
Currently KPBA has been in regular use in European steel works for more than 10 years. Once again, the improved operation stability
in the production blast furnaces - Table II1 demonstrated effectiveness of EBF in pellet development at LKAB.
Improvement of the pellet quality
Great successes have been achieved with the introduction of the 100% LKAB’s olivine pellets as ferrous burden into blast furnace
ironmaking operation since 1980s. To further improve the blast furnace performance with the use of 100% olivine pellets a new ideas
of coating the olivine pellets with slag formers,
which was inspired by the successful technique
Table III. Some main process parameters in the EBF trials
of coating direct reduction iron ore pellets, was
MPBO-3
MPBO-O
MPBO-D
MPBO-Q
put forward in the year of 2000. After a series
46.8
47.2
48.2
47.0
ηco
of theoretical investigations and laboratory tests,
PV bosh
8.9
9.0
8.3
8.3
pellets coated with different flux materials were
4.18
4.25
4.37
4.15
Productivity, t/m³⋅d
produced and put into trials at LKAB’s
Fuel rate, kg/tHM
552
541
537
549
EBF. Table III presents a comparison of some
major process parameters of the trials4.
In comparison with the operation of standard olivine pellet – MPBO-3, the performance of the EBF was indeed improved by the use of
the coated olivine pellets. The gas utilization was increased, while the fuel rate was decreased as shown in the table. The reason could
be that the coating materials may have enhanced the slag formation process in the furnace and permeability of the burden column2.
EBF for Improving the Performance of Blast Furnace
O2 in blast & Productivity
Reducing agent, kg/tHM
As it has been demonstrated that
EBF can well simulate the
550
45
commercial blast furnaces2, the
oil rate, kg/tHM
Coke rate, kg/tHM
interest of using EBF to improve
O2 in blast, vol%
Productivity, t/m²∙d
450
40
the performance of production
furnaces are always there. One
example was the trial for one of
350
35
LKAB’s customers to test the
oxygen enrichment and oil
250
30
injection rate in 1998. The
production furnace had a working
volume of about 1100 m³, an oil
150
25
rate of about 100 kg/tHM and an
oxygen ratio of about 27% in
50
20
blast. It was intended to enhance
the production rate and to
1
2
3
4
5
Case
decrease the coke rate through
Figure 3. Variations in coke rate, oil injection rate, and productivity with O2 increase in blast
increases
in
the
oxygen
enrichment and oil injection.
Therefore trials of different levels of oxygen ratio and oil injection rates were planned and conducted at LKAB’s EBF in 1998. The
major aims were to find appropriate ratio between oxygen enrichment and oil injection rate (oxygen/oil), the influences of the increase
in oxygen enrichment on productivity, as well as to achieve better understanding of the process behaviors with high oxygen and oil
injection rates.
The trial results clearly showed that with an increase in oil injection rate and the corresponding O2 enrichment ratio in blast, the coke
rate could be decreased, and the replacement ration between oil and coke was about 1:1 even when oil injection rate reached to a value
of about 200 kg/tHM - Figure 3. The furnace stability and thermal state did not deteriorate with the decrease in coke rate, which was
compensated by the increase in oil injection rate. The productivity could be increased too by about 1% with each 1% increase in O2
enrichment ratio in blast2.
EBF for Deeply Understanding the inside Phenomena of the Blast Furnace
As the standard metallurgical tests are not sufficient to evaluate the behaviors of burdens inside the blast furnace6, the EBF became
already from the first day when it was erected a very important tool for deeply understanding the inside phenomena of the blast
furnace ironmaking process. The measures usually taken are on-line probing of burden materials and dissection, as well as the further
studies of the probing and excavation samples.
One example of the studies of probing samples
was to find out the effects of different coal
types for pulverized coal injection as well as
the PCI rate on the reduction behaviors of
pellets for 100% pellet blast furnace operation7.
Figure 4 and Figure 5 show the influences of
coal type and coal injection rate on reduction
disintegration and reduction degree of pellet
respectively. It can be seen that with the highvolatile coal the reduction degree of pellet was
higher and in the mean time more reduction
disintegration might have occurred because of
more fines in the probing sample
correspondingly. The temperature around the
upper shaft probe inside the furnace could vary
from 600 to 900°C depending on the wall or
centre positions. The result might indicate
that high reduction rate of pellets can cause
more disintegration of pellets during
reduction. Process parameters must be
optimized to gain a suitable reduction rate,
avoiding reduction disintegration of burden
and achieving stable operation.
Figure 4. Particle size distribution of the probing samples from upper shaft probe
To achieve deeper understanding of the inside
phenomena of the blast furnaces, dissections
of nitrogen quenched EBF process were
carried out over 20 of 25 campaigns so far.
Dissection
is
conducted
like
an
archaeological excavation, and as it is
possible the original burden layers are
followed for sampling according to a
predetermined plan. In the mean time the
position, shape and characteristics of each
individual ferrous burden layer in the EBF
Figure 5. Reduction degree of the probing samples from upper shaft
will be documented in details. Further
analyses of excavation samples e.g. chemical
and mechanical properties, even characterization of microstructure by optical microscopy and SEM depending on the need, are usually
performed. One of the important aspects of the inside phenomena through the dissection and further analysis of the excavation
samples is to understand the reduction behavior of the burden, e.g. reduction degree and reduction disintegration.
For one campaign, 2000 pellets from 250 excavated samples were thoroughly studied by LKAB and SINTEFF Norway jointly and the
results were visualized 3-dimensionly through a specially designed computer program. Profiles of iron oxides distribution, reduction
degree as well as reduction disintegration of the pellets in the burden column could be directly displayed on a computer screen. More
detailed digitalized information regarding the properties mention above could be obtained by clicking on each sampling point on the
screen. Figure 6 presents distributions of wüstite and reduction degree of pellet samples in the burden column1,8.
Figure 6. Distributions of wüstite (left) and reduction degree (right) of pellet in the EBF
(darker points higher reduction degree)
The most interested inside phenomena is actually the cohesive zone, namely, its position, dimension and constitution. Different
cohesive zone were found through the dissections of the EBF, and in principle could be mainly classified by “reversed V”, “W” and
flat shape like a “slices of toast” in the furnace9. Layer structure of coke and solidified metallic iron or combined metallic iron and slag
was quite obvious as in Figure 7. The dimensions and
positions of the cohesive zone could be affected by a
number of factors, for instance, gas flow, productivity,
injection etc. besides the high temperature metallurgical
properties of the ferrous burden. The high temperature
properties of the burden materials could determine to a
large extent the position of the cohesive zone. But it
becomes more difficult to predict the dimensions and
location of the cohesive zone when mixed burden e.g. two
or more ferrous burden are used, even with the similar
operation conditions.
EBF for a Sustainable Ironmaking
Since 1993 SSAB Luleå works has been charging coldbonded briquette (CBB) which is made of blast furnace
flue dust, briquette fines, BOF sludge etc. The ratio of flue
dust in the CBB varied in a range of about 24-36%. It was
found that the dry flue dust amount increased from 20
Figure 7. A piece of the cohesive zone
kg/tHM in 1999 to 30 kg/tHM in 2001 and the strength of
CBB decreases with the increased use of flue dust in the CBB. To make a full use of flue dust and to reduce the coke consumption in
the blast furnace process for a environmental friendly ironmaking, the idea to inject the flue into blast furnace tuyere was put forward.
After a feasibility study of injecting flue dust into the blast furnace, a pilot scale trial was planned and carried out at LKAB’s
EBF. Figure 8 shows a schematic view of the injection system for co-injection of pulverized coal and flue dust. As the flue dust
injection was in operation, a separate vessel was mounted and connected to the fluidization chamber of the coal injection system with
a volumetric screw feeder. The mixture of PC and flue dust was then injected into each tuyere through separate lines.
5-day trials were conducted successfully without any blockage problem in the
injection system. The furnace process was quite stable with an average
injection rate of about 23 kg/tHM flue dust. The coke rate was reduced by
about 32 kg/tHM and in the mean time the furnace thermal state did not
deteriorate. By considering the differences in the hot metal temperature and
the [%Si] between the
Table IV. Flue dust injection trial results
reference and injection
Reference Injection
periods as well as the
Coke, kg/tHM
444
412
dust
injection,
a
PCI, kg/tHM
101
103
decrease in total fuel
Flue dust, kg/tHM
23
rate of about 11
kg/tHm
was
HM temp. °C
1461
1448
reached. Table IV
[%Si]
2.18
1,78
presents a comparison
Slag vol. kg/tHM
144
145
of some key process
parameters10.
Figure 8. Schematic view of injection system
Inspired by the EBF trial result, a full-scale trial of injecting flue dust together
with pulverized coal into a production blast furnace was performed at No. 3
BF SSAB, Luleå Works11. The trial results indicated that it is possible to
inject BF flue dust into a production furnace without disturbing the process
stability and thermal state. The carbon and iron in the flue dust could be well
utilized through injecting back into the BF. The technique can be a good
solution to increase the amount of materials recycled in an operation where
lack of sintering facilities. These days the co-injection of the flue dust
together with pulverized coal has become a standard operation at SSAB.
EBF for Developing New Technology – ULCOS TGRBF
ULCOS stands for Ultra–Low Carbon dioxide (CO2) Steelmaking. It is a consortium of 48 European companies and organisations
from 15 European countries
that
have
launched
a
cooperative
research
&
development initiative to
enable drastic reduction in
CO2 emissions from steel
production. The consortium,
led by a core group including
LKAB, consists of all major
EU steel companies, of
energy
and
engineering
partners, research institutes
Version 1
and universities and is
900°C
financially supported by the
European commission and the
25°C
core memebers. The target of
the ULCOS programme is to
reduce the CO2 emissions of
today’s best steel production
routes by at least 50 percent12.
Figure 9. Process flow of the three versions of the TGRBF
Top Gas Recycled Blast Furnace (TGRBF) is one of the research sub-projects in the ULCOS programme. The concept - Figure 9
relies on separation of the top gas of the blast furnace so that the useful components – CO+H2 can be recycled back into the furnace
and reused as reducing agents. This would reduce the amount of coke needed in the furnace. In addition, injecting oxygen (O2) into the
furnace instead of preheated air removes unwanted nitrogen (N2) from the gas, facilitating CO2 Capture and Storage (CCS).
In-depth theoretical studies of different blast furnace processes with top gas
recycling were carried out based on mathematical modelling to select the
appropriate process concept for pilot trials. Four versions of the TGRBF were
proposed for further studies. Laboratory tests regarding the reduction and melting
behaviours of the burden as well as burden structure under the TGRBF process
conditions were conducted to obtain the suitable burden structure for the ULCOS
blast furnace. Feasibility and safety studies of preheating the CO-rich recycled gas
were performed to ensure the safety for gas recycling. Coal gasification trials with
pure oxygen were accomplished in both laboratory and pilot scale to provide
information for designing tuyere.
To verify the feasibility of the concept it was decided to carry out pilot scale trials
at the LKAB’s EBF for Version1, 3 and 4 of the proposed TGRBF.
Improvement of the EBF
To guarantee the safety of heating and transporting the recycled CO-rich reducing
gas as well as a smooth running of the trial, a series of improvements on the EBF
and its auxiliary facilities were accomplished before trials.
• New hearth tuyeres for TGRBF process were designed and manufactured
• Shaft gas injection system - Figure 10 consisting of 3 shaft tuyeres and gas
distributors were developed and mounted on the EBF for testing version 1
Figure 10. Gas injection system of TGRBF
and 4 of TGRBF concept13
• Pulverized coal injection system was adapted for using much higher amount
of oxygen
• Measures for enhancing the process safety and reliability were taken
• VPSA plant for removing CO2 of the top gas was constructed by Air Liquide and tested through some conventional EBF
campaigns before the TGRBF campaigns
After the modification and the reconstructions of the EBF, the pilot plant is able to simulate both conventional and ULCOS TGRBF
processes. Figure 11 shows the schematic view of the TGRBF process with CO2 removal unit – VPSA plant14.
The Trials
3 campaigns each for about 7-week were dedicated to the trials of different versions of ULCOS TGRBF in 2007, 2008 and 2010. The
ferrous burden consisted of about 30% LKAB’s pellet and 70% sinter and with one week exception of 100% LKAB’s pellet. Coke,
pulverized coal and slag formers were provided by SSAB, Luleå Works.
To facilitate the evaluation of the trial results a relative constant production rate of about 1.5 t/h was targeted through the campaigns.
Three levels of PCI rates of about 130, 150 and 170 kg/tHM were tested to optimize the coal injection in the proposed TGRBF process.
When testing the version 4 of the TGRBF efforts also were paid to the optimal use of the recycled gas in both hearth and shaft tuyeres.
Figure 11. ULCOS blast furnace at LKAB’s EBF plant
During the trial profiles of gas temperature and compositions across two diametrical directions were consecutively measured using
two shaft probes. Burden samples in the lower region were taken lively too by the inclined probe. Before the blow-out of the trial
baskets containing different sinter and pellet samples were charged into the furnace for studying the behaviours of different ferrous
burdens under the TGRBF conditions. During the blow-out the EBF was quenched by blowing nitrogen from the top to the hearth
tuyeres. After the quenching the EBF was dissected independently by LKAB and samples were taken during the excavation for further
study. Internal state of the burden column, shape and position of the cohesive zone as well as the raceway status were observed and
recorded.
14,15
The Trial Results
Based on three campaigns at LKAB’s EBF it could be concluded that it is possible to operate the EBF with the full ULCOS blast
furnace processes. With appropriate measures heating-up of CO-rich recycled top gas as well as transport and injection of heated COrich gas are feasible and safe. The EBF and VPSA operations were smooth with satisfactory results. A carbon saving of up to 27% or
even higher depending on the recycled gas flow and temperature could be achieved and a reduction in CO2 emission, in case CO2
storage from VPSA was counted, of about 76% was possible; which was corresponding to a decrease in CO2 emission of about 65%
for an integrated steelmaking plant with hot rolled coil as product15. The EBF has been accepted by project partners as a great tool for
developing TGRBF process and further campaign may be under planning.
Further Steps
Research activities reported in this paper is only some examples of research projects carried out using EBF at LKAB. Actually the
EBF has been undergoing extensive modifications and improvement to equipment since erected and there have been a more wider
range of research and development projects conducted with the EBF so far. Comprehensive evaluation of EBF trials and comparisons
to production furnaces have lead to a deeper understanding of the blast furnace rionmaking process as well as how the EBF can be
used to further improve the modern ironmaking technologies, especially for a sustainable and environmental friendly development.
The success story of LKAB’s EBF will be continued with the full cooperation with LKAB’s customers and partners. For the near
future, besides the use for product development, more campaigns will be possibly dedicated to the trials for decreasing the CO2
emission from BF process, likely e.g. for new TGRBF and the Japanese CO2 mitigation program for steel industry – Course 50.
ACKNOWLEDGEMENTS
The authors are grateful to all colleagues and staff at LKAB, MEFOS and project partners as well as contractors that contributed to the
EBF operation and campaigns. The financial support from the Research Fund for Coal and Steel of the European Community is
greatly appreciated. Thanks also to all project partners of ULCOS TGRBF and co-workers of the campaigns especially those from
LKAB and MEFOS for their great contributions to the trials.
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