Some Questions On Interrelated Processes Going On In The Blast Furnace

IN spite of the great amount of operating experience and of studies directed toward elucidation of the interrelation of the several processes going on in the blast furnace, the present picture of its operation is based largely on indirect evidence and on speculation. The reason for this unsatisfactory situation is the extreme difficulty of making direct observations and significant measurements while the furnace is operating, and of translating laboratory experience to the conditions obtaining in the smelting process. Yet there are questions that can be investigated with some promise of a definitive answer; and it is the purpose of the present paper to set forth some of these questions, as a basis for discussion, which may, it is hoped, lead to active work on some of them. In order to provide a starting point for this discussion, some views held tentatively by the writer are outlined, along with a certain amount of evidence gathered from operating records and interpreted on the basis of the ideas expressed. These opinions may prove not to be pertinent, and may well not be in accord with the opinions of others; they have been included to encourage others to do likewise and on purpose to provoke informal discussion. In this way it should be possible to transcend the limitations of formal papers; to bring forth suggestions of new hypotheses or new methods of investigation; and to promote better understanding between investigators and operators in this difficult field. The statements made express the present views of one physical chemist who is not too familiar with all the difficulties of maintaining these enormous reaction vessels in reasonably smooth and economical operation; who, however, is persuaded that some of these difficulties would be less formidable if surer knowledge of the several interrelated and concurrent processes were available and made use of. For these difficulties arise largely, it is believed, from variation in conditions which the operator must meet as best be can, and should lessen as these conditions can be brought under control so that they are either made substantially constant or the variations are neutralized by compensating methods. A. VARIATION IN BURDEN AND IN MIXING OF CHARGE To the scientific investigator, who aims to control the conditions of experiment and to limit the number of variable factors, the most perplexing aspect of the blast-furnace process is that nothing seems to remain constant for long. Variations of burden seem to be unnecessarily frequent; and, even if the charge were constant from hour to hour, its constituents usually are not mixed as intimately as they might well be. It is understandable that separate layers of coke and of ore, also separate layers according to size, promote permeability and the