2005 LKAB's EBF - The Learning Curve

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Tu1 Efficient blast furnace operation: High productivity, low coke rate - 3
LKAB'S EXPERIMENTAL BLAST FURNACE - THE LEARNING CURVE

Lawrence Hooey, LKAB, Box 952, Lule, Sweden (Currently: Rautaruukki Oyj, Ruukki
Production, P.O. Box 93, 92101 Raahe, Finland)
Bror-Erik Skld, MEFOS, Box 812, 97125 Lule, Sweden
Lena Sundqvist kvist, SSAB Tunnplt AB, 97188 Lule, Sweden.
Matti Seppnen, Rautaruukki Oyj, Ruukki Production, P.O. Box 93, 92101 Raahe, Finland
Guangqing Zuo, LKAB, Box 952, 97128 Lule, Sweden, Guangqing.zuo@lkab.com

Abstract

Since 1997 LKAB has run 14 campaigns of 6-12 weeks each in the experimental blast furnace
(EBF) located at MEFOS in Lule, Sweden. The plan at that time was 5 campaigns with testing
of new pellet grades aimed at both 100% pellet operations typical in the Nordic region, and at
mixed burdens of pellets and sinter typical in middle Europe. A great deal of information has
been gathered, a new pellet developed and the use of the EBF has been extended to include much
more research than was originally planned. In addition, the furnace has been used extensively for
applied research by LKAB, by LKAB's customers and various research organisations and other
companies. Such testing includes, for example, testing of injection techniques with coal-flux co-
injection, high oxygen/oil injection, blast conditions testing with high moisture, investigations of
scaffolding, evaluation of equipment and measurement devices such as a new type of bell-less
top. The furnace is providing an excellent springboard to both the next generation of blast
furnace pellets and blast furnace operations in the years to come. The EBF will be modified for
testing of full oxygen blast furnace concepts for reduction of CO
2
emissions within the scope of
the ULCOS project.

Introduction

LKAB's experimental blast furnace, Figure 1, was commissioned in 1997 after study of the
world's previous experimental furnaces. The EBF was planned for 5 campaigns of about 6 weeks
each for development and testing of LKAB's experimental pellets. The furnace was built to
overcome the gap between laboratory behaviour of pellets and that of industrial application as it
has been LKAB's experience that laboratory testing is not sufficient for the development of new
pellet types.
1,2,3,4
Within the first few campaigns it became clear that the EBF was a very
valuable tool not only for development of pellets but for other research and development of the
blast furnace process. To date 14 campaigns have been run. From campaign 3 and on, the EBF
has been used in various external research projects such as ECSC, Jerkontoret, and also by
individual companies.

Welcome Publications
The 5th European Coke and Ironmaking Congress, June 12-15 2005, Stockholm, Sweden
Tu1:3 - 2
Inclined
upper c. - 4.3 m
lower c. -5 m
Upper shaft -1 m
Lower shaft -3.45 m
Tuyere -6 m
Tuyere level probe (during stop)
Working volume 8.2 m
3
Hearth diameter 1.2 m
Working height 6.0 m
Tuyeres 3
Tuyere diameter 54 mm
Top pressure (max) 1.5 bar guage
Injectants Coal/oil/propane
Oxygen enrichment up to 40%
Blast temperature c. 1200
o
C
Production 30 - 40 t/d
Reducing agents 500 - 580 kg/thm

Figure 1. Experimental blast furnace showing in-burden probe positions. Upper and lower shaft probes are either
material or gas/temperature. Inclined and tuyere probes are material probes only.

Development of the EBF as a tool for BF research

In order to broaden the use of the furnace to other research areas and increase its reliability in
burden testing, the furnace has undergone many improvements since commissioning. The
availability of the EBF is over 99% of planned operation time.

Basic design of the Experimental BF

The EBF is equipped with all systems typical for a full-scale blast furnace operation (Figure 2
shows general layout). Starting with material handling system, the material is screened to 6 mm -
50 mm and then transported to bins and from there weighed on precision scales before charged
to the furnace via a single skip and a bell-less type top.

The coal injection system is a dense phase type system with a capacity of more than 300
kg/THM. The coal flow is individually controlled for each tuyere. Furthermore the furnace is
equipped with injection systems for oil and gas that can be co-injected with oxygen. The
injection and raceway are constantly monitored by video cameras at each tuyere that are viewed
from the control room.

The hot blast is produced in propane-fired pebble bed type hot stoves, supplied by ATZ in
Germany. The stoves are very efficient and can produce hot blast up to 1300
o
C. The stoves can
be brought up to operational temperature from room temperature in two days and be cooled
down in three days. The hot blast valves and the vent valve is water cooled.

The furnace is insulated in order to reduce heat losses and the cooling of the bosh is more as a
back up in case of severe wear of the refectory. Beside the bosh cooling it is only the tuyere and
Tu1:3 - 3
jumbo coolers that are cooled by water. The cooling system is a closed system with heat
exchanger and a basin with cooling tower for the primary system.

The furnace was originally equipped with a bell type top in combination with movable armours.
The furnace operates today with a new type of bell less top with extremely flexible charging
possibilities designed and supplied by Zimmermann & Jansen.

The top gas is cleaned by a dust catcher for the cursed grain size and the finer part of the dust is
cached by a venturi scrubber in combination with a wet ESP. The top pressure (max 2,5 bar (a))
is controlled by two control valves after the dust cleaning system and then flared over the roof of
the BF building.

The tapping of the furnace is made by conventional tapping machines. A pneumatic drilling
hammer and a hydraulic mud gun are used. The metal and slag is tapped into a movable sand bed
and cooled, weight and stored for sale.

The EBF is equipped with two gas analyzers, one for the top gas and one for the shaft gas
probes. The pressure drop over the furnace is monitored by pressure gages in five levels at two
positions per level. The vertical temperature profile can be monitored by a device that allows a
thermocouple to be inserted anywhere over the radius of the furnace top. The thermocouple will
follow the burden down to a temperature where it burns off.

The furnace is equipped with two shaft probes and one that penetrates the cohesive zone (Figure
1). The inclined probe for the cohesive zone sample solids and the other two samples both solids
and gas/temperature.

Figure 2. Basic layout of the EBF. Moving from left to right are the material storage bins, coal injection pressurised
chambers, skip system, pebble heaters, furnace, tapping equipment and top-gas cleaning system.
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Improvements in EBF after commissioning

Many improvements have been made since commissioning in order to facilitate an increasing
variety of testing as well as to extend the lifetime. Some milestones are shown in Figure 3. To
name a few improvements: the control systems have been improved to accommodate an
increasing number of measurements; the number of materials bins has been increased to
accommodate two more feed materials; the injection systems have been modified to allow for
co-injection of slag formers, high rates of oil injection, and combined oxygen injection; new
ventilation and dedusting systems; new XRF hot metal and slag analyzer; new Zimmerman &
Jansen bell-less top. Testing began with ferrous burden quality, but has extended much further
to include injection techniques, blast conditions, coke quality and so on.

Commissioning
First tests: with sinter; with flux injection; oil injection; first customer trial
First test with lump ore
Blast O2 40% + oil 200 kg/thm; coke rate kg/thm; first tuyere coke probing
Introduction of Z&M bell-less top
First use of propane injection
Testing of ilmenite injection
Testing of coke quality
Installation of EBFs own hot metal/slag analyzer
1__2__3__4__5__6__7__8__9__10__11__12__13__14
Campaign
Commissioning
First tests: with sinter; with flux injection; oil injection; first customer trial
First test with lump ore
Blast O2 40% + oil 200 kg/thm; coke rate kg/thm; first tuyere coke probing
Introduction of Z&M bell-less top
First use of propane injection
Testing of ilmenite injection
Testing of coke quality
Installation of EBFs own hot metal/slag analyzer
1__2__3__4__5__6__7__8__9__10__11__12__13__14
Campaign

Figure 3. Milestones in the development and use of the EBF

Comparison of the EBF to commercial furnaces

One important factor to consider was how the EBF compares to the behaviour of commercial
furnaces. Tables 1, 2 and 3 show the comparison of several industrial furnaces to the EBF with
various ferrous burden structures. The general result was that the EBF had a reductant rate about
50-70 kg/thm higher that of industrial furnaces. This is attributed to higher heat losses in the EBF
and hot metal silicon about 1% higher than in industrial furnaces.

Table 1. EBF test vs. SSAB Tunnplt No. 3 furnace.
EBF SSAB Lule No. 3 (2004)
Burden Pellets 100% Pellets 100%
Injection Coal Coal
Coke rate 439 326
Injection rate 100 139
Total Fuel rate 539 464

Table 2. EBF compared to Bremen furnace no. 2.
EBF Bremen no. 2
Burden Pellets 46%, Sinter 54% Pellets 49, sinter 44%, lump ore 7%
(2 week test period)
Injection Oil Oil/plastic
Coke rate 474 406
Injection rate 54 48/21
Total fuel rate 528 475

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Table 3. EBF compared to Duferco Furnace
EBF Duferco Clabeq no.6 (2000)
Burden Pellets 73%, Lump ore 27% Pellets 80%, Lump ore 20%
Injection Coal Coal
Coke rate 477 391
Injection rate 100 118
Total Fuel rate 577 509

It was first thought the EBF's small hearth and tapping conditions with tapping times of 5
minutes with a tap to tap time of 1 hour and hot metal silicon values over 1% would make
comparison of hot metal quality and slag behaviour to commercial operations difficult. However,
as can be seen in section 2.1, hot metal and slag behaviour with respect to sulphur and alkalis is
similar to commercial furnaces.

BF Research and Development Areas

LKAB Product development

LKAB introduced the Olivine-fluxed pellet in the early 1980's replacing acid pellets. The Olivine
pellets have been the mainstay of LKAB's blast furnace pellet production up to the development
of the KPBA high iron content acid pellet, commercialised since 2000. The advantage of the
KPBA pellet has been found to be in stability of softening/melting properties in the mixed
burden with basic sinter.
5
Figure 4 shows a comparison of the resistance to gas flow for a
condition whereby the furnace is going from colder to warmer conditions. The KPBA pellets
show a consistent permeability for a given heat level as measured by Si in hot metal.

Hot Metal Si wt%
7,5
0,0 0,5 1,0 1,5 2,0 2,5
PV-Bosh
PV-bosh = (Blast Pressure
2
-Top Pressure
2
)/(bosh gas volume)
1,7
*
constant
LKAB Olivine pellets + sinter + fluxed pellets
LKAB Acid pellets + sinter + fluxed pellets
6,0
6,5
7,0

Figure 4. EBF data showing improved stability of pressure drop for LKAB acid pellets (KPBA) in a mixed
burden compared to KPBO in a mixed burden. Arrow shows increased pressure drop when going from cold to hot
conditions, as for example during start-up after a stop.
5

Further development example: Coating of blast furnace pellets

The Olivine pellets have been highly successful in 100% pellet operations, however LKAB has
been working towards improving both the properties of the olivine pellets and trying new
concepts for 100% pellet burdens. A high iron content fluxed pellet is one possible pellet that
was tested at the EBF and in full-scale.
6
Operation with the fluxed pellet was acceptable.
However, slag formation appeared to give less favourable alkali output versus desulphurisation
capacity, Figure 5. After careful examination of various material samples from EBF testing, it
Tu1:3 - 6
appeared likely that applying a coating to the surface of the fluxed pellet could improve the slag
formation and pellet descent. This treatment appears to be successful in the EBF, Figure 6, and
development of the concept is continuing.

0
25
50
75
100
0,2 0,4 0,6 0,8 1,0 1,2
K2O Content of Slag
(S)/[S]
MPBO (>80%) MPB1 (>60%)
MPBO
MPB1
0
25
50
75
100
0,1 0,3 0,5 0,7 0,9
(K2O) wt%
(S)/[S]
MPB1
MPB1 - olivine coated

Figure 5. S and K
2
O behaviour in slag in commercial furnace
6
; Figure 6. EBF testing of olivine coating of MPB1
MPBO = standard LKAB olivine pellets showing improved relationship between sulphur
MPB1 = experimental fluxed pellets and alkali distribution.
6

General applied research

As well as being used directly for product development, the overall blast furnace process is being
investigated with several examples given below. Testing of various conditions in the EBF
involves no risk to industrial production and is ideal for this type of research.

Blast conditions - high moisture

In two separate campaigns, the effect of blast moisture at varying flame temperatures where
tested.
7
Table 4 shows the general conditions in each campaign and test. The experiments were
undertaken to establish at which point the blast moisture and/or flame temperature become
critical factors in the BF operation in furnaces running with little or no oxygen enrichment.

In the first test, Test A, an increase of blast moisture from 17 g/nm
3
to 36g/nm
3
had little impact
on fuel rate, but stabilised the burden descent, Figure 7. In a second test, B, even higher moisture
contents were used, and a clear limit was reached between 35g/nm
3
and 52 g/nm
3
, Figure 8. The
total fuel rate about the same up to 35 g, but it was necessary to increase the fuel rate
dramatically between 35 and 52g (or at flame temperature between 2110 and 2000
o
C).

Table 4. Testing conditions for effect of increased blast moisture
TEST PERIODS

Test A. Oil injection
Injection
rate
kg/thm
Blast
moisture
g/nm
3

Blast
temperature
o
C
Flame
Temperature
o
C
Test time
hours
1 42 17 1198 2260 48
2 44 36 1198 2135 40
Test B. Propane Injection
1a* 29 16 1198 2220 70
1b* 31 16 1199 2220 33
2 30 35 1199 2110 42
3 30 52 1199 2000 78
Period 1 a and b: Period 1a the furnace was underfueled and becoming colder; period 1b was
after a charging disruption and the furnace was overfueled and becoming warmer (see Figure 8).

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0
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u
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d
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c
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t

r
a
t
e
c
m
/
m
i
n
32
34
36
38
40
42
44
46
48
50
E
t
a

C
O
Burden descent cm/min Eta CO
Moisture 16 g/nm
3
35 g/nm
3

Figure 7. Burden descent and gas utilisation with increased blast moisture up to 35g/nm
3
.

0
1
2
3
4
2
0
0
3
-
0
9
-
2
9
2
0
0
3
-
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9
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-
1
0
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1
3
[Si]
wt%
325
375
425
475
525
Coke rate
kg/thm
HM Si % Coke rate kg/thm
Charging disruption
1a (16 g/nm3) 1b
(16 g/nm3)
2
(35 g/nm3)
3
(53 g/nm3)

Figure 8. Second test of blast moisture with blast moisture up to 53 g/nm
3
.

Raceway dissections

The EBF offers the possibility to inject different materials into each tuyere. The effect of
different injectants on raceway conditions have been examined by operating the furnace.
8
For
example, in one test each tuyere was injected with different conditions for 8 hours prior to
nitrogen quenching. Condition of each raceway was then evaluated. In this example, Figure 9,
the tuyeres had 1) no injection; 2) coal; and 3) coal + BOF slag. Clear differences were visible in
raceway condition with tuyeres 1 and 3 showing porous end of raceway, whereas tuyere 2
showed a clear development of a hard dense birds nest composed of acidic components of coke
ash. Further testing has been conducted using propane, oil and coal injection.
9

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0.40 m
0.45 m
0.50 m
Porous end
Birds nest
Porous end
No injection
Coal &
BOF-slag
Injection
Coal
injection
1
2
3
1
2
3
1
2
3

Figure 9. Coal rate corresponding to equivalent 98 kg/thm (if same level for all three tuyeres) for tuyeres 2 and 3,
and tuyere 3 containing equivalent 37 kg/thm BOF slag mixed with the coal.

Blast furnace chemistry and mineralogy

Using both the in-burden probes and samples taken from dissections after nitrogen quenching of
the furnace, it is possible to examine in detail the reactions occurring in different materials and
various positions in the furnace.

For example, alkalis are known to affect burden materials significantly. Figure 10 shows the
process of potassium absorption into relic olivine grains found in olivine pellets.
10

Carburisation phenomena have also been examined, which is difficult to due in industrial
furnaces as sampling is virtually impossible. However, the meltdown of burden and flow
characteristics in the melting and dripping zones are critical to furnace performance. Figure 11
shows examples of iron slightly carburised by CO gas.
11
Due to difficulties to analyse carbon in
microprobe, the carbon content has been estimated by the pearlite, cementite, ledeburite and
ferrite contents.

Combining controlled laboratory meltdown tests with examination of the same materials
removed from the EBF using the in-burden probes is also proving information about the
reliability and application of laboratory experiments in the evaluation of high temperature
properties.
12

The details of the ferrous burden morphology evaluated by microscopic examination as well as
chemical data for selected excavations is being placed in a visual database developed by Sintef
that allows for easy handling of large quantities of information.
13
Several excavations have been
systematically mapped and recorded into the database.

a) b)
Figure 10. Reaction of olivine in olivine pellets taken from the EBF inclined probe
10

a) Image of olivine grain under transmission light with crossed polarisation
b) Backscattered scanning electron image of the same grain.
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Point 27: enstatite (Mg
2
Si
2
O
6
); Point 28, 29: complex pyroxene (Fe,Mg,Ca)
2
SiO
6
with 3-5% K
2
O
dissolved; point 30: high FeO content silicate glass.

a) b)
Figure 11. Reflected light images of two pellets removed from the inclined probe of the EBF.
11
Carbon content can
be estimated from the quantity of pearlite found. Sample a) contains circa 0.3% C (40% pearlite); sample b contains
circa 0.6% carbon (80% pearlite). Scale bar is 20 micron.

Direct customer-Oriented tests

Co-injection of additives with PC

The effects of injection of BOF slag and BF flue dust together with coal have been tested in the
EBF.
14
Each additive was transferred into the coal fluidisation chamber using a volumetric screw
feeder (Figure 12). The mixture of PC and additive was then injected into the three tuyeres of the
EBF. The goal of BOF slag injection was to modify the meltdown behaviour of the burden,
lessening the extremes of slag chemistry in the cohesive zone, and also to add basic components
into the raceway to help prevent acid birds nest formation with high levels of coal injection.
Flue dust injection provides a method to recycle the dust and utilise the carbon content as a fuel.
Injection of hematite containing BF flue dust results in higher FeO content of the tuyere slag.
15

The increase of FeO and the slightly increased basicity improves the melting properties of tuyere
slag a birds nest is less easily formed.

Figure 12. Injection of fluxes with PC
Tu1:3 - 10

As can be seen from Table 5, the Si content of hot metal and the consumption of reducing agents
significantly decreased when BOF slag or BF flue dust are co-injected with coal. Decreased Si
content of hot metal reduced the consumption of coal and coke but this great effect cannot be
expected at a large BF. However, the decreased slag amount and reuse of C in BF flue dust can
be expected to be similar in an industrial furnace. Full-scale test at SSAB Tunnplt in Lule
indicates that carbon contained in the BF flue dust can be efficiently used and replace some coal.

Table 5. Summary of tests with co-injection of additive with coal

BOF slag injection BF flue dust injection
Co-injectant kg/tHM 0 25 36 0 23.4
PCI kg/tHM 98 93 98 101 103
Coke kg/tHM 439 440 428 444 412
Pellet A % 70 70 0 100 100
Pellet B % 30 30 100 0 0
%Si in HM % 1.28 1.04 1.00 2.18 1.78
HM Temp C 1416 1426 1423 1461 1448
Slag vol. kg/tHM 136 110 101 144 145

Cold-bonded pellets (CBP) trial

Since 1978, when the sinter plant was closed down, the blast furnaces at SSAB in Lule have
operated with 100% pellet burden together with a cold bonded briquette produced from
recyclable by-products. Amounts of 40-85 kg/tHM of cold-bonded briquettes have been charged
to the blast furnaces at SSAB Tunnplt in Lule since 1993. The effect from charging high
amounts of cold bonded agglomerates on the BF process is evaluated in the EBF by producing a
cold-bonded pellet (CBP) with almost the same raw materials as normally are used to produce
the briquettes.
14
The pellet contains approximately 40% Fe and 12% C and has a basicity B
2
=
2.1. With a high level of cold-bonded pellets, the addition of fluxes (limestone and LD-slag)
becomes unnecessary. Charging of CBP results in decreased consumption of reducing agents,
see Table 6 mainly due to their content of C and metallic Fe. However, the amount of flue dust
also increased.

Table 6. Raw materials used during the test of cold-bonded pellets made from by-products.
kg/ tHM Test 1 Test 2 Test 3 Reference
Pellets 1290 1209 1193 1388
CBP 149 299 344 0
Coke 402 390 389 402
PCI 120 122 114 131
Reducing agents 522 512 503 533

The effect of size distribution of pellets on the BF behaviour

Decreased filling levels in pellet bins at BF No 2 at SSAB Lule have resulted in severe process
disturbances on a number of occasions. These disturbances are shown by changes in burden
permeability and gas utilisation followed by slips and changed heat level of hot metal. Practical
studies carried out at SSAB Tunnplt in Lule showed, contrary to what was expected, no
increase in the amount of fines charged to the blast furnace but an accumulation of coarse
Tu1:3 - 11
material at low bunker levels. The EBF was used to test the behaviour by charging pellets with
varying size fractions.
14
The experiments confirmed that a high ratio of pellets greater than 12.5
mm caused production disturbances.
Table 7 summarise the results from the tests with different particle size distribution of pellets.
The gas utilisation of the first period of testing, when pellets of the reference fraction are
charged, varies as a result of some process disturbances, including a chilled hearth that was
remedied just before the start of the test. The blast furnace performance deteriorates gradually,
when the particle size distribution of charged pellets includes increased ratios of pellets of
fraction 12.5-16mm and +16mm. The gas utilisation decreases and starts to vary more when
pellets of particle size distribution 66% 9.5-12.5 mm/ 22% 12.5-16 mm/ 12% +16mm is charged.
The burden descendent also becomes irregular. Some small slips occur at the same time as
EtaCO reaches minimum values of approximately 44. After the start of charging pellets of
particle size distribution 33/37/30, the gas utilisation decreases further and starts to vary even
more. The blast furnace performance improves rapidly when pellets of particle size distribution
100/0/0 are charged into the EBF with the gas utilisation increasing to an average of 50%. When
charging the pellets of particle size distribution 33/37/30 a couple of small slips occurred, as well
as some periods with quite long intervals between the dumps. The behaviour of the EBF
correlates well with what was experienced in the industrial furnace.

Table 7. Average of process data related to particle size distribution of charged pellets.
Particle size distribution
9-12.5 / 12.5-16 / +16
EtaCO
x
EtaCO

Burden
descent
cm/min
x
Burden
descent

72 / 28 / 0 49 1.4 4.8 0.6
82 / 17 / 0 49 1.2 4.5 0.5
66 / 22 / 12 48 1.3 4.0 0.6
33 / 37 / 30 47 1.6 4.2 0.5
100 / 0 / 0 50 1.3 4.3 0.3

The process disturbances were mainly attributed to
decreased indirect reduction rate and increased direct reduction of the coarse pellets
fines generation in the shaft caused by disintegration of the coarse pellets during
reduction
increased softening and melting temperature interval caused by residual FeO in the
pellet core of the coarse pellets

High oxygen and oil rate testing

Typical oil and oxygen rates in Rautaruukki furnaces are 100 kg/thm oil and 27% O
2
in blast.
The oil price compared to coke price makes the use of oil economic. In order to test the limits
and effect of high oxygen/oil operation, and EBF trial was carried out. The aims of testing very
high oil and oxygen rates in the EBF were to:

clarify and get experimental data on production increase with high oil and O
2
rates
define reducing agents dependency on high oil and O
2
rates
gain knowledge about BF process at high oil and O
2
rates, and test where maximum
points lie due to heat balance effects
provide values for production cost estimates based on experimental data

Tu1:3 - 12
A BF mass/heat balance model developed by bo Akademi was used to evaluate the EBF data.
The EBF operation was quite close to target process values and little correction was necessary to
estimate outcome of the target values. Table 8 shows the results of the test periods.

Results showed that even at high oxygen and oil rates, the productivity increase was circa 1% for
every 1% increase in blast oxygen rate at constant bosh gas rate. With an increased bosh gas rate
at constant oil rate, periods 3 and 4, the production rate increase was 1.5% for 1% increase in
blast O
2
.

The relation between oil injection and coke rate showed that the replacement ratio remained
close to 1:1, Figure 13, indicating that increasing the hydrogen content continued to lower the
direct reduction rate and kept the total reductant rate constant.

Table 8. Summary of testing of high oxygen and oil rates in the EBF for Rautaruukki.
Period 1 Period 2 Period 3 Period 4 Period 5
Length (stable operation) hours 32 45 40 34 27
Blast O
2
% 28 34 37 39 39
Oil rate kg/thm 100 142 168 169 203
Coke rate kg/thm 404 362 333 335 302
Total reductant rate kg/thm 504 504 501 504 505
Bosh gas volume nm
3
/h 2165 2172 2312 2297 2375
Productivity t/m
2
/d 29,2 30,8 31,5 32,5 30,8
Specific blast consumption Nm
3
/thm 1081 916 858 799 814

275
300
325
350
375
400
425
90 120 150 180 210
Oil rate kg/thm
Coke rate
kg/thm

Figure 13. Coke rate versus oil rate in the EBF

Collaborative industrial research programs

Starting from the dissection of campaign 3 in 1998, the furnace has been used extensively in
support of various European (ECSC, RFCS) and Nordic (Jernkontoret, MiMer) research projects.
Examples of several projects are found below, with these and other projects described recently in
MEFOS News.
16

Accretion formation

An ECSC project of which MEFOS is a partner, is the study of formation of accretions
(scaffolds) in the blast furnace. Evaluation of the scaffold formation process has been done by
tracking heat losses on the furnace walls and comparing to scaffolds mapped and sampled from
the EBF during dissection. Detailed chemical and mineralogical study, example in Figure 14,
Tu1:3 - 13
provides information on the processes leading to the formation that provides information for
strategies to minimise the problem. A statistical model has been developed that is being tested
industrially.

Hearth protection by Ti injection

MEFOS is a partner in a project to study the protection of the furnace hearth by formation of
titanium carbo-nitrides that deposit on the hearth walls. The goal of this is to test the protection
of the hearth for longer furnace campaign life. The type of material, position of injection and
volume of injection are being considered. Evaluation is made by injection of Ti-compounds,
Figure 15, in two campaigns just prior to quenching, and study of the distribution of titanium
carbo-nitrides in the hearth of the EBF.

Figure 15. Injection of Ti-
compounds in a separate lance at
EBF tuyere.
16

Figure 14. Analyses of a scaffold from an EBF dissection
16

Changes in microstructure of coke while passing the blast furnace

The behaviour of coke in the blast furnace is being investigated in an ongoing ECSC project in
which MEFOS is a partner.
16
This has involved evaluation of BF operation using different grades
of coke as measured by tradition laboratory quality tests (CSR, CRI). The coke is also sampled
during EBF operation, and excavated coke with evaluation using chemical and mineralogical
techniques.

Status of EBF as a tool in Blast Furnace Research

From the 14 campaigns to date, the EBF has undergone extensive modifications to equipment.
There have been a wide range of research and testing done with the EBF, with only a part of
research discussed in this paper. Extensive evaluation of EBF tests and comparison to industrial
furnaces has lead to a deeper understanding of how the EBF can be used for blast furnace
research and development.

Tu1:3 - 14
The EBF has clearly proven its usefulness as a research tool both for LKABs original purpose
of effective pellet development but also general blast furnace research and development. The
EBF will continue to provide opportunities of advanced research and development in the future.

One of the major projects requiring significant modification and multi-national involvement is
the modification of the EBF to a full-oxygen blast furnace in support of the ULCOS project.

References

1. M. Tottie, 'LKAB's Experimental Blast Furnace at Mefos/Lule', 57
th
Ironmaking Conference,
Toronto March 22-25, 1998, ISS, pp. 1587-1590.
2. A. Dahlstedt, M. Hallin and M. Tottie, 'LKAB's Experimental Blast Furnace for Evaluation of
Iron Ore Products', Scanmet I, Lule, Sweden, MEFOS, pp. 235-245.
3. L. Hooey and B. Sundelin, 'Evaluation of High Temperature Properties of High Iron Content
Fluxed Pellets', 57
th
Ironmaking Conference, Toronto March 22-25, 1998, ISS, pp. 1609-
1614.
4. L. Hooey, J. Sterneland and M. Hallin, 'Evaluation of High Temperature properties of blast
furnace burden', 1
st
International Meeting on Ironmaking, Belo Horizonte, Brazil,
September 24-26, 2001, pp205-220.
5. L. Hooey, J. Sterneland and M. Hallin, 'Evaluation of Operational Data from the LKAB
Experimental Blast Furnace', 60
th
Ironmaking Conference, Baltimore, March 22-25, 2001,
ISS, pp. 197-208.
6. L. Hooey, M. Hallin and K. Raipala, ' Development of fluxed blast furnace pellets with
application of coatings', METEC Congress 2003, 3
rd
International Conference on Science
and Technology of Ironmaking', Dsseldorf, VDEh, June 16-20, 2003, pp. 256-261.
7. J. Riesbeck, Effekter av blsterfukt p LKAB:s experimentmasugn, Master's thesis, Lule
University of Technology, 2004.
8. J-O Wikstrm, Peter Sikstrm, L. Sundqvist and G. Zuo, Improved Slag Formation in the
Blast Furnace by Co-injection of Basic Fluxes, Together with Pulverised Coal, Through
the Tuyeres, International BF Lower Zone Symposium, Wollongong, Australia,
November 2002, paper no. 18.
9. P. Sikstrm and B. Lindblom, 'Different reductant injectants influence on BF raceway',
Scanmet II, 6-9 June, 2004, Lule, Sweden, MEFOS, pp. 417-427.
10. E. Eliasson, Formation of Potassium Slag in Blast Furnace Pellets, Master's thesis, Uppsala
University, 2004.
11. K. Raipala, On hearth phenomena and hot metal carbon content in blast furnace, Doctoral
thesis, Helsinki University of Technology, 2003.
12. N. Eklund, 'Trials with mixed burden in the LKAB Experimental Blast Furnace', Scanmet II,
6-9 June, 2004, Lule, Sweden, MEFOS, pp. 353-364.
13. G. Tranell, T. Hagelien, L. Kolbeinsen, A. Dahlstedt and M. Hallin, 'Results and
Visualisation from the First Campaign in LKAB's Experimental Blast Furnace in Lule,
Sweden', 59
th
Ironmaking Conference, Pittsburgh, March 26-29, 2000, pp 125-136.
14. L. Sundqvist-kvist, Co-injection of Basic Fluxes or BF Flue Dust with PC into a BF
Charged With 100% Pellets- Effects on Slag Formation and Coal Combustion, Doctoral
thesis, Lule University of Technology, 2004.
15. K. Kushima, M. Naito, K. Shibata, H. Sato, H. Yoshida and M. Ichida, Iron ore injection
into blast furnace raceway, ISS Ironmaking Conf. Proc. 1988, pp 457-466.
16. MEFOS News, April 2004, ed. K. Edfast, MEFOS, Lule, Sweden.

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