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The blast furnace operates as a countercurrent exchange process whereas a bloomery does not. Another difference is that bloomeries operate as a batch process whereas blast furnaces operate continuously for long periods. Continuous operation is also preferred because blast furnaces are difficult to start and stop.
The blast furnace method is expected to survive into the 22nd century because of its efficient rate of iron production at competitive costs compared with other iron-making methods. Blast furnaces keep on improving with adaptations arising from new technologies driven by rising global demand, yet the main chemical process remains the same. But ...
For blast furnaces, direct reduction corresponds to the reduction of oxides by the carbon in the coke. However, in practice, direct reduction only plays a significant role in the final stage of iron reduction in a blast furnace, by helping to reduce wustite (FeO) to iron. In this case, the chemical reaction can be trivially described as follows ...
The blast furnace is similar in structure to a cupola furnace used in iron foundries. The furnace is charged with slag, scrap iron, limestone, coke, oxides, dross, and reverberatory slag. The coke is used to melt and reduce the lead. Limestone reacts with impurities and floats to the top. This process also keeps the lead from oxidizing. The ...
The coking plant that feeds a battery of blast furnaces is just as expensive as the blast furnace and requires a specific quality of coal. [ 64 ] [ 65 ] Conversely, many direct-reduction processes are disadvantaged by the costly transformation of ore into pellets: these cost on average 70% more than raw ore. [ 66 ]
This used a blast furnace to make pig iron, which then had to undergo a further process to make forgeable bar iron. Processes for the second stage include fining in a finery forge. In the 13th century during the High Middle Ages the blast furnace was introduced by China who had been using it since as early as 200 b.c during the Qin dynasty.
During this continuous process more raw materials are placed at the top, and as the coke moves down, it must withstand the ever-increasing weight of the materials above it. It is the ability to withstand this crushing force, in addition to its high energy content and rapid combustion, that makes coke ideal for use in blast furnaces.
This is an accepted version of this page This is the latest accepted revision, reviewed on 31 December 2024. Manufacturing processes This section does not cite any sources.