The molten products of the blast-furnace operation are separated by the settling of the matte and slag under the action of gravity, and the production of the economically cleanest slag depends upon the fulfilment of those conditions which allow of the most perfect downward settling of the small particles of matte. The three main requirements for efficient settling, apart from the composition of the slag, are:—
In each of these essentials, the method of external settling, as now conducted at modern smelters, best satisfies the conditions required for successful work.
The present practice is to make no attempt to conduct settling in the blast furnace, but to run the products through and out of the furnace with the greatest speed attainable, and to allow the matte and slag sufficient time and opportunity to settle and separate in some independent and external vessel, which stores the matte and allows the clean slag to run straight away to waste.
The former method of inside settling gave rise to many difficulties in practice, but objections were urged against the external settler, to the effect that heat might be wasted by the abstraction of hot materials from the furnace to an exterior vessel, and that the settling would not be efficiently conducted outside, as in the very hot interior of the smelting furnace. Modern practice has proved conclusively that both objections are groundless. Such heat as is carried away by the continual stream of molten material can usually be well spared in the modern plant, which is driven so rapidly that an abundant supply of exceedingly hot matte and slag pass through to the settler, whilst the results of every-day working demonstrate the efficiency of the external settler, which cannot be equalled, far less surpassed, by any method of inside settling, under modern smelting conditions. Thousands of tons of slag pass daily through the settlers, clean enough to discharge straight to the dump, the copper contents rarely exceeding 0·40 per cent.
(b) The modern conditions of rapid working and large output render the use of external settlers practically essential, owing to the double work of smelting and separating being no longer confined to one and the same vessel. The aim in present practice is to exercise the smelting function only of the furnace, and to do so to its fullest capacity, smelting for matte of the desired grade as rapidly as possible, and therefore running the products through the furnace in a constant rapid stream and allowing them to settle quietly outside. Under these circumstances the furnace itself smelts most economically and efficiently.
It will be recalled that present-day practice involves the subsequent treatment of the fluid matte—product in the converter, so that whilst the former methods of working might have possessed certain advantages for the settling and storing of matte in the small furnaces, and then tapping out and casting into cakes for subsequent treatment, such methods have practically no application to modern systems of working.
Internal settling almost invariably leads to the accumulation of debris, of chills and of any infusible masses of material which may be produced in the furnace, occasioning delay in the operations, waste and difficulty in working, and so interfering seriously with the speed and continuity of the smelting, as well as decreasing the output of the furnace. On the other hand, a rapid flow of hot molten material through the furnace not only tends to prevent this formation of chills or accretions, but greatly assists in the dissolution or removal of such as might be formed. Should the production or collection of such masses be transferred to the settler instead, they are more readily attacked and remedied without interfering with the continued operation of the furnace.
Further, the nature of the hearth which would be most satisfactory for internal settling is not at all suited for modern smelting conditions. The ordinary water-jacketing would have too marked a cooling effect on the hearth for the materials to remain sufficiently hot and fluid to allow of proper settling, whilst a brasque or similarly lined hearth suitable for such settling would, under the present conditions of rapid driving and intense reactions, be unable to withstand the highly corrosive and abrasive action to which it would be subject, so that breakouts, necessitating delays and repairs, would constantly occur. Water-jacketing in this portion of the furnace is indeed an essential for modern conditions, and consequently rapid driving and quiet internal settling in the same area are quite incompatible. The modern fore-hearth, on the other hand, is accessible and easy of repair, and in the event of any trouble occurring therein, the furnace itself can continue its smelting activity to the full, since other suitable arrangements can readily be made for temporarily dealing with the products.
Fig. 38.—Water-Jacketed Blast Furnace (48 inches by 240 inches). Lower Portion,
indicating Air and Water Connections, Bottom Supports,
End Slag Spouts, etc. (P. & M. M. Co.).
(c) The functions of the blast furnace in the modern smelting scheme are particularly dependent upon the employment of the external settler in conjunction with it. The work of the furnace plant is to produce as rapidly as possible, a supply of suitable grade matte for the converters; large quantities of hot fluid matte must be available at a moment’s notice, and such demands are often very erratic, being dependent on the working of the converter plant and the refining furnaces. It is essential to the successful operation of the blast furnaces that the manager should be in a position to work his furnace as rapidly and continuously as possible, which is best attained by making the output independent of irregular tappings of matte just when required by the converter department. The settlers, in exercising the function of reservoirs for matte, from which the converter department may draw at will, allow of regularity of working and rapidity of output in a manner possible in no other way. The only alternative, using internal settling, would consist of tapping out matte at regular intervals and casting such material when it is not immediately required, a wasteful and unnecessary practice incompatible with modern ideas of smelting work.
During the early stages of the development of smelter plant, the use of reverberatory fore-hearths received considerable attention, the principle being to build a fire-box in communication with the settler, so as to ensure a sufficient supply of heat in the vessel for efficient settling. Modern furnaces however, usually supply a large enough quantity of very hot and fluid matte and slag as to allow of very efficient separation without the use of extra heating, providing the position and construction of the settler is suitably planned, as will be described in due course.
Dimensions.—The modern blast furnace is a long, narrow, water-cooled shell, rectangular in plan. The dimensions, particularly the length, vary greatly, being regulated according to the anticipated output of the furnace-unit. The size is generally expressed in terms of the internal dimensions at the tuyere level, which represents the smelting area. The width of the modern furnace varies usually from 44 to 56 inches, according to the blast pressure, method and speed of working, concentration to be effected, and so forth. The length in many cases is between 15 and 25 feet, when the furnace may be conveniently worked in connection with one large settler. The capacity of such a unit naturally depends on the conditions of working; it may be taken roughly as from 4 to 6 tons of material per square foot of hearth area per twenty-four hours.
Foundations.—The furnaces are built upon a foundation which is necessarily very strong, being usually either of solid rock or of concrete.
Bottom Plate.—The bottom plate of the furnace usually carries part of the weight of the lower tier of water-jackets as well as the furnace burden, and is supported, some distance above the ground, on screw-jacks leaving an air-space below the furnace, which allows of convenient access for repairs or adjustment. The height of the construction is thus raised to a convenient distance for adjustment to the discharge to the settlers. The bottom plate should consist of sectionised water-cooled cast-iron plates bolted together, with a thin layer of brickwork placed above, to protect them from the corrosive influences to which they are subject. There is a slight slope towards the slag-notch. The actual working bed of the furnace is however, a chilled crust of material which sets on this bottom owing to radiation below, and which, when suitable precautions have been taken, usually adjusts itself naturally whilst the furnace is in operation, by what may be termed automatic radiation. Thus, apart from the water-cooling devices, if the working bottom wears down towards the metal plates, the loss of heat by radiation through the thin layer of material causes a chilling effect which leads to a thickening of the crust. Should the crust thicken unduly and so threaten to interfere with the discharge, the radiation is decreased owing to the thickness; and the high temperature which prevails upon this layer causes a partial melting so that it gradually becomes thinner again—thus regulating itself for the most part automatically.
Fig. 39.—Tapping Breast of Blast Furnace, Cananea (see p. 139).
Fig. 41.—Transverse Section through Modern Blast Furnace,
showing Arrangements of Boshed Lower Jackets, Upper Jackets
and Plates, Stays and Supports, etc.
Water-Jackets.—The usual height of the modern furnace, as reckoned from tap-hole to charge floor, is roughly from 14 or 16 feet up to 20 feet, water-jacketed all the way. The sides and ends of the furnace are constructed of sectionised water-jackets arranged horizontally in tiers and vertically in panels. There are usually two, occasionally three, tiers, suitably stayed and supported. The practice as regards the shape and arrangement of the jackets varies greatly. It was formerly not uncommon to work with three tiers of jackets for the sides; of these the lower tier extended only from the sole-plate to the level of the slag-notch, forming practically the crucible jackets, the height varying from 2 feet 6 inches to 4 feet. These were most used when the discharge to the settler was situated at the side wall of the furnace. Above these jackets was situated the second tier through which the tuyeres passed; these build up the boshes of the furnace, and are termed the “bosh” or “tuyere” jackets. In most modern furnaces these two tiers of lower jackets are replaced by one set of panels of from 7 to 10 feet in height, the jackets being given a slight slope towards each other at the bottom, so as to form a very small bosh angle; the contraction is about 8 inches. This improvement does away with a good deal of the jointing otherwise necessary near the hottest parts of the furnace, and thus lessens the danger of leakage at these points. The water-cooled breast-plate containing the opening for the escape of the products is now put in position as a separate piece, well secured to the rest of the jacketing (Fig. 39). Above the lower tier of jackets is placed the upper series, often from 7 to 9 feet in height, which carries the walls of the furnace up to within a few feet of the charging platform. These jackets are parallel, and no bosh is given (see Fig. 41).
The end jackets are usually built in two tiers only, the upper, 7 feet to 7 feet 6 inches, as a rule, and the lower, 8 feet to 9 feet 6 inches, according to circumstances; in the smaller furnaces the end wall may sometimes consist of a single jacket only. They are vertical, no end bosh being allowed. The end jackets are each single panels, whilst the side walls are built up in panel sections, the width of which vary, but are often 7 feet to 7 feet 6 inches wide, the panels being bolted or clamped together and strongly stayed.
The water-jackets are constructed of flanged steel plate, the inner sides of which are 5⁄16 to ⅜ inch thick, the outside ¼ to 5⁄16 inch. The seams are flanged outwards, so as to prevent joints, etc., being exposed to the inside of the furnace. The water space between the two plates of the jacket is from 3 to 4 inches.
It is usual to support the weight of these jackets on I-beams carried by the upright columns; very strong bracing and tieing is also necessary in order to prevent the side walls from bulging by the great pressure to which they are subjected. In order to protect the jackets themselves from buckling by the forces acting upon them, they are strengthened inside the water space by a series of ┻ bands, which run vertically downwards between the plates, and are rivetted to the outer side—this device is found not to interfere unduly with the proper circulation of the water. Leakage between the joints of the separate jackets is prevented by asbestos packing. In spite of the strong binding and bracing of the walls in this manner, the connections are so devised as to allow of their being unfastened very easily, so that jackets may be readily disconnected and taken down when it becomes necessary to do so.
Arrangements for the water supply to the jackets vary considerably. In localities where a plentiful supply is available, each jacket has its independent outlet and inlet pipes; in other cases it is common to arrange an independent feed to each set of panels, water being supplied first to the jackets of the lower tier, and being discharged from them to the jackets situated above. The supply pipes for the various jackets branch from water main pipes running at the sides of the furnace.
The tuyere or bosh jackets are pierced horizontally at intervals of about 1 foot, with a line of 5-to 7-inch holes for the fitting in of the tuyere pieces. These are formed of steel thimbles, of ⅜-inch metal, which have a slight taper, fitting secured against the inner plate and rivetted to the outer one, thus allowing of ready replacement when necessary (see also Fig. 40). Above the side jackets of the furnace there is usually a heavy mantel-plate, 2 feet to 2 feet 6 inches high, with a sloping front, and surmounting this are apron plates, 1 foot 6 inches to 2 feet high, inclined at 45°, constituting a hopper which directs the charge towards the centre of the furnace in such a way as to keep the fines nearer to the middle line, and thus leave the sides of the charge more open, in order to ensure more regular working.
Superstructure.—The jacketing, together with the apron and mantel plates carry the structure up to the charging floor. Above this is the superstructure with the arrangements for taking off the furnace gases, and for the feeding of material for the charge. In many cases the general practice still prevails of constructing the walls of this portion of brickwork, often about 14 feet high, surmounting this with a hood of metal from the top or sides of which large off-takes carry the furnace gases to the dust chambers, and thence to the flue system and stack. Modifications in the design of the blast-furnace superstructure have been, however, in course of progress at many works, particularly in connection with the employment of automatic or mechanical charging appliances and the taking-off of the gases below the feed-floor level. This is specially the case at plants operating the pyritic process and where the gases are to be utilised for acid manufacture, as well as in connection with the treatment of smelter fume. Several furnaces are also at work using either metallic water-cooled or air-cooled tops, from which the removal of accretions is stated to be very readily effected.
Some of the most recent developments in the design of blast-furnace superstructure have been described by Emmons in reviewing the experiments at the Copperhill Smelter, Tennessee. The gases here are used for acid-making, and are sent to Glover towers under some pressure. The furnace top consists of cast-iron corner-posts and dividers, the walls and ends laid up with brickwork, surmounted by a tubular top of the Shelby type from which the gas off-takes lead. The horizontally pivoted doors open inwards and fit tightly. These arrangements are stated to be very satisfactory.
Fig. 43.—Showing Upper Jackets, Apron and Mantel Plates,
and Superstructure of Blast Furnace, Anaconda.
The charging platform, suitably supported on vertical columns, runs at the upper level, being provided, on either side of the furnace, with tracks of rails for the charge cars. The charging doors usually correspond in position to the panels of water-jackets, and are situated along the whole length of each side furnace-wall, the bottom of the charging opening being flush with the floor. They are generally moved up and down in the grooved guides of the upright columns between them, and are of sheet steel suitably strengthened, from 6 to 7 feet wide and 4 feet 6 inches to about 5 feet high, supported by wire-rope and chains, and operated by compressed air cylinders.
The Air Supply to the Blast Furnace.—The quantity of air required by the blast furnace varies very widely with the class of work, rapidity of output, character of charge, and general smelting conditions. It may be stated roughly as being from 300 to 500 cubic feet of air per minute per square foot of hearth area, at a pressure of about 40 to 50 ozs. per square inch.
The rotary blower of the Roots or Connersville type is very well suited for the supply of these enormous quantities of air at moderate pressures, but for blast at higher pressures the air leakage becomes excessive, and piston-driven blowing engines become almost a necessity. Such improvements have, however, been made in rotary-blowing appliances within recent years that most blast-furnace plants are equipped with blowers of the rotary type, which are found highly satisfactory. The air is brought along blast mains of considerable size—about 30 inches diameter—to the furnace building, thence to the bustle pipes of 24 inches diameter, which surround the furnace, from which branch off the pipe connections (5 or 6 inches diameter) for the tuyeres. The practice of equipping each furnace with its own blowing unit is fairly general, making the necessary reserve connections in case of temporary breakdown; many smelters, however, adopt the system of delivering the air from all the engines into one large common air main, making the necessary connections from this to each separate furnace. The importance of avoiding leakages is recognised, and the requisite valves for regulating and controlling the air supply are arranged for.
From the bustle pipe the air passes down the pipe connections which are attached by flanged joints, thence to the tuyere pipes, which are of cast-iron, the blast being regulated by valves. The actual form of tuyere employed varies considerably, each smelter usually having its own special devices for the convenience of repair, renewal, and fixing, as well as for valve regulation and punching. The tuyere is held against the face of the jackets by bolts, leakages being prevented by asbestos packing.
The tuyeres are usually 4½ to 5 inches in diameter, and are generally placed about 12 inches apart. Air is supplied only through the side jackets, and not at the ends of the furnace.
Heating the Air Blast.—The advisability of heating the air-supply for copper blast-furnace smelting has been the subject of very considerable discussion, the question requiring consideration both with respect to its influence on the rationale of the smelting operation as well as from the economic standpoint. The matter is dealt with more fully in connection with pyritic practice, from which point of view Peters has reviewed the subject exhaustively. It may be here stated that there appears to be no advantage in preheating the air when the true pyritic process is operated, and actual trial has resulted in the rejection of the method at the smelters practising this work.
Where, however, coke fuel to any considerable extent is employed on the charge, a supply of heated air through the tuyeres may result in an increased rapidity of smelting, as well as in the production of hotter and more fluid slags. Especially in partial pyritic smelting and more particularly when working charges which contain but little sulphide and where the employment of much coke is not advantageous, the use of preheated blast may be economically very useful. In such cases, the heat production in the furnace is not so fundamentally bound up with the thermo-chemical reactions of slag formation as it is in true pyritic smelting, and therefore the enhanced intensity of combustion of coke-fuel at the tuyere-zone by the use of hot air may exert an important influence in improving the furnace operation and in decreasing the amount of coke-fuel required. In many such instances indeed it has been chiefly the economic factor with reference to the cost of installing and operating suitable devices for warming the air-supply which has determined the question of adopting this system. As is well known, the use of a supply of heated air causes a largely increased calorific intensity from the combustion of coke, resulting in higher temperature at the tuyere-zone, under which circumstances the charge materials are smelted more rapidly, and the resulting products are more fluid, whilst slags of higher silica content (sometimes economically advisable) can be conveniently worked with.
The devices employed for the preheating of the blast vary considerably—cheapness, capacity, simplicity in design and operation being the main essentials.
The utilisation of the waste heat from the smelting furnaces or products would suggest itself as an economical method for accomplishing the warming of the blast, but in practice several difficulties are encountered in efficiently making use of this heat. Heat is available from two sources, either from the furnace gases or from the hot slag. The very successful operation in cast-iron smelting, of hot-blast stoves worked by the “waste gases,” cannot, however, be applied to copper blast-furnace smelting, since the gases in this case do not possess similar calorific value owing to the small proportions of carbon monoxide present. Further, the temperature of these gases is not sufficiently high to allow of the effective application of the regenerative principle using brickwork chambers. In consequence, the use of metal pipe-stoves offers the only method of utilising the heating values of the furnace gases, but their comparatively low temperature does not afford sufficient heat for the warming of the large quantities of air which are required at the tuyeres.
The much higher temperature of the reverberatory furnace gases offers, however, much greater scope for their utilisation in this respect, if both classes of furnace happen to be in operation at the plant and if they are conveniently situated for the purpose.
At several smelters, blast furnaces have been equipped with hot-blast “tops” for the purpose of preheating the air supply, the air-heating pipes being exposed to the gases in the upper portions of the furnace. The Giroux blast-heating device has been installed on furnaces at smelters in Mexico and Arizona, whilst at others in the same localities, the Mitchell system of baffle passages has been successfully used. The Kiddie system of running the blast pipes through the dust chambers has been tried at Tyee, B.C. The advantages of thus utilising the heat of waste gases have generally, however, been found to be more than balanced by the extra costs involved.
Efforts have been made to use the heat contained in molten slag for warming the air, but owing to the low conducting power of these materials, and the difficulty of bringing extended surfaces in close contact, the method has not proved itself very efficient. Blast is occasionally warmed by passing the air through tunnels in which bogies of molten slag are allowed to remain for some time.
When methods of utilising waste heat from the furnace products fail, the fuel-heated iron pipe-stove is generally employed. Since the temperatures required are comparatively low, and the margin of profit involved by the use of hot blast is usually small, the use of the cheapest class of fuel available is imperative; but many classes of fuel unsuitable for other purposes may find useful application for this work.
The stove is of the usual cast-iron pipe form, designed to give the maximum exposing surface, suitably strengthened and protected from direct action of the fire. Much valuable information on the advantages, disadvantages, and appliances for blast heating was afforded by the smeltermen who contributed to the symposium on “Pyrite Smelting,” which Rickard edited for the Engineering and Mining Journal.