Chemical Interpretation of Tuyere Drill Cores

from the Ruukki Blast Furnaces - Coke and Fines

Olavi Kerkkonen and Riku Kanniala

Rautaruukki Oyj
P.O. Box 93
FI-92101 Raahe
Finland
Tel: +358 205911
E-mail: olavi.kerkkonen@ruukki.com and riku.kanniala@ruukki.com

Key words: blast furnace; tuyere, drilling, coke, fines

INTRODUCTION

Ruukki Production, Raahe, manufactures liquid iron in two medium sized blast furnaces of 8 m hearth diameter. The effective
volume of blast furnace No. 1 is 1086 m3 with 21 tuyeres and furnace No. 2 is 1174 m3 with 18 tuyeres. Preheated, heavy
distillation residue oil injection is used on both furnaces. The main difference in the furnaces is in the charging, which on BF1 is a
charging of two bells with two chambers and movable armours and on BF2 a compact bell-less top.

Core drilling towards the furnace centre through the tuyeres, during stoppages, is one method of obtaining information about blast
furnace conditions below the shaft. In order to obtain information regarding factors affecting our coke consumption and fines
formation, tuyere drillings were ordered from Corus, England in 2001. As a result of the good information received from these
drillings we decided on construction of our own drilling machine (Figure 1), which was built for us by the Finnish company
Geomachine Oyj. Our first tuyere drillings were carried out at the end of 2002. At the moment we have in all a data bank of 41
tuyere drill cores in use. In general it can be said that; it is seldom that a tuyere drilling profile matches our concept of optimised
blast furnace working situation.

This paper deals in short with our concept of how to interpret tuyere drill cores based on the chemical composition of coke and
fines. In the following some drill core examples are chosen for chemical comparison of +20 mm coke and fines -0.5 mm: two
tuyeres drilled during the same stoppage (II/BF1) with maximum coke consumption, coke fines at maximum (III/BF1), the same
feed coke with decreased coke consumption and top dust amount on BF1/IV and BF2/V and reducing agent consumption at
maximum level (VI/BF1). Beside demands for coke properties there is arisen need to optimise charging practice.

Figure 1 Tuyere drilling machine

 BLAST FURNACE PRODUCTIVITY VERSUS FEED COKE

The main indicators for assessing BF operating conditions are the gas distribution and heat loss trends, with which iron production
and coke rate are strongly correlated. The reference No. 1 in Tables I–III represents an example of production conditions and coke
behaviour which for long time maintained performance of the blast furnace.

Table I shows BF production data as the mean values for the 4 days before the drilling examples. Slag charging at BF1/II to
improve deadman performance increased coke consumption. A BF1 charging system directed ferrous burden too much towards
centre furnace. An effect of small coke, charged with ferrous burden, on an increase in BF 2 deadman fines is one alternative in
comparison of BF1/IV and BF2/V.

Table I Blast furnace production data

HM HM HM HM Red.
Drilling Coke Oil Slag
Prod. C Si S agent
number kg/tHM kg/tHM kg/tHM
t/m3/d % (%) (%) kg/tHm
I 3.39 4.52 0.45 0.048 353* (40)** 98 451 196
II 3.00 4.62 0.55 0.041 372 (34) 95 467 260
III 3.47 4.39 0.41 0.065 349 (34) 110 459 218
IV 3.54 4.47 0.42 0.050 340 (33) 113 453 218
V 3.37 4.54 0.42 0.044 333 (44) 109 443 216
VI 3.34 4.55 0.41 0.042 360 (37) 113 473 224

Note: The values are mean values for the 4 days before the drilling
* Including coarse +36 mm coke and small coke of 12–36 mm
** Charged with the ferrous burden

Table II shows BF operation data as the mean values for the 4 days before the drilling exercise. The blast temperature and oxygen
content are adjusted to maintain a constant flame temperature, to contribute towards maximisation of iron production rate.

Table II Blast furnace operation data

Flame Blast Blast O2 Blast Heat Top
Drilling
temp. temp. vol. enrich. pressure loss dust
number o o
C C kNm3/h Nm3/h bar Gj/h kg/tHM
I 2220 1089 138 10500 2.51 44.7 4.3
II 2310 1159 135 9400 2.45 83.5 4.5
III 2320 1199 137 12200 2.48 71.8 4.4
IV 2300 1187 141 12400 2.53 77.3 3.7
V 2290 1171 139 12300 2.58 53.2 3.8
VI 2280 1185 140 12200 2.58 74.4 4.3

Table III shows the average coke values for the week of the core drill examples. Generally speaking, a clear correlation between
coke consumption and CSR index of the coke, between 61–71%, has not been found in the production running of the blast
furnaces. There is arisen an important role of high Irsid 40 and low Irsid 10 to decrease formation of coke fines during charge
descent in blast furnaces. In comparisons, higher ash content and lower basicity value of the coke have come up as the main factor
improving CSR, but as one factor to increase fines at blast furnace tuyere level.

Table III Coke data*

Drilling CRI CSR Irsid 10** Irsid 40** AMS Ash SiO2/
Basicity***
number % (%) % % mm % Al2O3
I 24.1 65.3 19.0 52.0 66 9.6 2.01 0.15
II 23.7 65.6 19.3 50.5 64 10.0 2.16 0.14
III 25.1 61.7 20.8 45.8 61 11.5 2.29 0.11
IV 21.7 65.3 19.3 48.1 59 10.7 1.94 0.12
V 21.7 65.3 19.3 48.1 59 10.7 1.94 0.12
VI 21.9 65.3 19.8 49.8 62 11.5 2.26 0.11
* Sampling point at coking plant
** +20 mm coke
* Basicity: (Fe2O3 + CaO + MgO + K2O + Na2O) / (SiO2 + Al2O3)

Irsid 40 of about 50 % and the lowest possible SiO2/Al2O3 ratio/ash content for the coke can be recommended because the
combination is positively linked with productivity and fuel rate of the blast furnaces; this relationship probably being due to
decreased macro-porosity and tridymite-quartz dissemination in the coke. An increase of crystal size in the transformation of
quartz to tridymite (1) seems to affect fissure formation during coking, which can be seen, for instance, as smaller wharf coke size
and an increase in abrasion, Irsid 10. Moreover, at blast furnace temperatures of over 1500 °C all coke silicates begin to gasify
which increases coke micro-porosity and weakens its resistance to impact forces, being produced by upper charge weight and
tuyere blast.

TUYERE DRILL CORE

Figure 2 illustrates the visuals of the drill core pair IV/BF1 and V/BF2 which are divided into blast furnace sections; bosh,
raceway/graphitized/non-graphitized), bird’s nest and deadman. From case to case drill material is analysed in 25 cm or 50 cm
subsections.

Figure 2 Comparison of drill cores

BF2 showed increased development of a dusty deadman with the same coke and under the similar blast conditions. However, at
BF1 there was achieved a higher production rate at 0.17 t/m3/d (to maximum of 3.5 t/m3/d) which meant 7 kg increase in coke
consumption, 11 kg decrease in use of small coke and weaker gas distribution.

Figure 3 shows the distribution of -0.5 mm fines at tuyere level and accumulation towards the centre of the furnace. The deadman
appears to become totally blocked at a fines content of over 20%. The -0.5 mm fines is first sieved out from the drill cores and,
after magnetic separation of the rest material of the drill core, considered as a part of coarser non-magnetic drill core, consisting of
carbon and silicate materials.

30
0-0.5 m
0.5-1 m
Fines (%)

20 1-1.5 m
1.5-2 m
2-2.5 m
10
2.5-3 m

0
II (BF1/5) II (BF1/8) III (BF1) IV (BF1/C) V (BF2/C) VI (BF1)
Drilling exrecise

Figure 3 Fines distribution in drill core

Figure 4 shows the limits for ash content in fines. There is found two factors increasing amount of fines to maximum which are
ash factor and carbon factor. This paper focuses on the influence of silica and iron on the rate of coke degradation in the lower
part of the blast furnace. In this respect, traditional coke research and testing have given very little information. The chemical
analysis of +20 mm coke and -0.5 mm fines in the drill core is only the starting point in the study of coke degradation, which is
one part of the thermodynamically controlled blast furnace process.
 100
Ash factor

Fines (%)/ash in it (%)

80
Fines II (BF1)
Ash
60
Fines IV (BF1)
Ash
40
Carbon factor Fines V (BF2)
Ash
20

0
0 0.5 1 1.5 2 2.5 3
Distance from tuyere (m)

Figure 4 Limits for ash content in drill core fines

ORIGIN OF FINES AND PIECES

Figure 5 (V/BF2) shows what kind of fines originates into upward gas flow under raceway conditions in which coke textures
graphitize and silica reduces. One accumulation direction for the fines is bird’s nest and deadman. The appearance of coke fines
with mixed iron appears to be a sign of decomposition of coke surface structure, catalysed by attack of micro-sized iron into coke
lump. Iron in excess is routed through the raceway flame.

Figure 5 Micrograph of coke fines formed in raceway

Figure 6 shows the percentage of 10–20 mm pieces in the +10 mm drill core coke. A significant decrease in coke size is
concentrated in the raceway section and furnace centre.
 Mechanical decrease
in coke size
70

10-20 mm coke (%)

Chemical decrease
II (BF1/5)
in coke size
50 III (BF1)
IV (BF1/C)
VI (BF1)
30

10
0 1 2 3
Distance from tuyere

Figure 6 Percentage of 10–20 mm pieces in +10 mm drill core coke

An important reason for the decrease in size of raceway coke seems to be of a chemical nature and is connected with both higher
amount of silica in feed coke and increased iron contamination in raceway coke. The size decrease occurring in the deadman
centre is more in the nature of mechanical stress in shaft region and correlates with lower Irsid 40 and higher Irsid 10 for the feed
coke, the example III/BF1. Coexistence of the smaller deadman coke and the low deadman temperature are found, making
possible an increase in coke alkalis. However, there is no direct evidence of alkali influence on coke degradation.

Figure 7 shows the variation in porosity for +20 mm coke in the drill core III, this being the most fragmented sample and also
having the highest alkali content. The coke sections of 50 cm were crushed to 19–22.4 mm size from which the porosity of 50 g
pieces were measured by image analysis, this then representing the average porosity of the tuyere coke. Variation in coke porosity
is compared with FeO content in fines and Si content in drill core iron.

56 12
Fines FeO and iron Si (%)

Chemical factor
Porosity (%)

52 8 Porosity 520x
Mechanical factor Porosity 130x
Fines FeO
48 4 Iron Si

44 0
0 0.5 1 1.5 2 2.5 3
Distance from tuyere (m)

Figure 7 Coke porosity versus FeO in fines and Si in iron for drill core III

It is clear that mechanically weak feed coke tends to be fragmented by compression forces in coke chimney, the influence of
which is seen as a disappearance of coke pieces of high porosity in the image analysis of the tuyere centre coke. A significant
carbon gasification, which proves reaction with CO2 gas, cannot be detected inside deadman coke. In a hot raceway there are
several reaction alternatives affecting a lump decrease: (a) the coke surface abrasion, such as carbon texture graphitisation and
iron contamination on coke surface, and (b) internal decomposition, such as increased liberation of Si gas from silicates,
increasing silicification of iron phase and decreasing FeO content in it.

COKE CHEMISTRY

The drill core coke of over 20 mm was crushed, as in the NSC test procedure, and the -19 fraction used in the coke chemical
analyses. Depending on temperature and atmosphere variations in the blast furnace different elements gasify out of the coke or
impregnate the inner part of the coke.

Both iron catalyst and thermal graphitization decompose coke surface structure in raceway increasing abrasion tendency
(Figure 8). The fines clustered together in longer bird’s nest, intermixed with Ca-silicates which indicate contemporaneous
increase in oxygen potential. Heat transfer to furnace centre becomes slower that finally provides a platform for low temperature
compound accretions (V/BF2 and VI/BF1).
 16

12
II (BF1/8)
Raceway abrasion
III (BF1)
Fe (%)
8 IV (BF1/C)
V (BF2/C)
VI (BF1)
4

0
0 0.5 1 1.5 2 2.5
Distance from tuyere (m)

Figure 8 Iron distribution in drill core coke

Figure 9 shows the distribution in SiO2/Al2O3 ratio in the drill core coke. In the raceway the temperature is always high enough for
silica escape which is combined with an increase in pieces and fines of coke. Raceway heating leads to silica escape from the coke
and to the formation of simple chemical phases including alumina, Al2O3 and spinel, MgAl2O4, (2), which decreases the
SiO2/Al2O3 ratio in lumps to about 1.5. A low SiO2/Al2O3 ratio longer to furnace centre extent means a pronounced role of silica
escape in the formation of fines. The carbon textures, which contain less tridymite - quartz inclusions stand up better to abrasion
(generally isotropic texture).

2.4
Silicon reoxidation

1.9 II (BF1/5)
SiO2/Al2O3

III (BF1)
IV (BF1/C)
V (BF2/C)
1.4 VI (BF1)

Silica reduction
0.9
0 0.5 1 1.5 2 2.5
Distance from tuyere (m)

Figure 9 SiO2/Al2O3 distribution in drill core coke

Silica escape is punctuated by the appearance of a bird’s nest in which CaO and SiO2 (TiO2) contaminate the coke lumps and iron
begin to agglomerate to separate clusters. Mineral species detected by the EDS are tricalsium silicate, Ca3SiO5, dicalsium silicate,
Ca2SiO4, and perovskite, CaTiO3 which involve reoxidation of Si gas to active SiO2.

Figure 10 shows the alkali distribution in the drill core coke at tuyere level. Alkalis in coke increase as a function of temperature
falling towards the furnace centre. There is able to be estimated raceway length and temperature differences in deadman. To find
the parameters, which put a stop to silica escape from silicate phase and formation of spinel remnants, changing the reaction to
formation of alkali silicates, kalsilite, (K,Na)AlSiO4, and leucite type, (K,Na)(Al,Mg)(Si,Al)2O6.
 8

Temperature
-
6 II (BF1/5)

Alkalis (%)
+ - II (BF1/8)
III (BF1)
4
+ IV (BF1/C)
V (BF2/C
2 VI (BF1)

0
0 0.5 1 1.5 2 2.5 3
Distance from tuyere (m)

Figure 10 Alkalis in drill core coke

First of all alkali vapours react with Al-Si-silicates in coke and come fixed which bonding seems not to affect any big cracking
effect. No doubt the alkali silicates form spherules and irregular segregations, which are of larger size than the meta-mineral phase
(3). In the EDS analyses the chemical compositions closest to the parent particles are found in the centre parts of the aggregates.

The mechanical drum tests for the 19–22.4 mm deadman fractions after crushing and sieving of the +20 mm drill core coke gave
strength values, almost being independent of high alkali content, which are close to that of the feed coke. Instead high loss of
mechanical strength of coke at tuyere level is focused in the raceway section. An amount of volatile compounds in tuyere coke
correlates positively with high alkali content. Alkalis must be partly in the free form, which explains zero CSR values obtained in
the NSC test for coke from the centre of the deadman and notably higher values from the raceway.

FINES CHEMISTRY

The prevailing blast furnace atmosphere is recorded in the drill coke fines. The chemical composition of fines depends on BF
circumstantial factors. In order to maintain high oil injection and iron production, we increase the temperature, pressure and
oxygen content of the blast and this may easily make the longer and denser bird’s nest. A change in the shape of the cohesive zone
to that of a V with extra blocking of cooling deadman can be in contact with an increase in ferrous burden load towards the oven
centre, as a function of charging procedure and insufficient feed coke strength. The iron in deadman fines increases to maximum
and, because of agglomeration, in bird’s nest it is at minimum level (Figure 11). The cases III/BF1, IV/BF1 and VI/BF1 are of
interest concerning an influence of ferrous burden silicates on amount of fines.

30
II (BF1/5)
II (BF1/8)
Fe (%)

20 III (BF1)
IV (BF1/C)
V (BF2/C)
10 VI (BF1)

Bosh Raceway Bird's nest Deadman

0
0 0.5 1 1.5 2 2.5 3
Distance from tuyere (m)

Figure 11 Iron distribution in drill core fines

Figure 12 shows the variation in SiO2/Al2O3 ratio and alkali content in the fines. Under the tuyere conditions the SiO2/Al2O3 ratio
remains in 2 which emphasize abundance of coke pieces and temperature being enough for silica escape. A higher ratio without a
change in alkalis shows appearance of oxidizing atmosphere and formation of slag fines (blast practice). The SiO2/Al2O3 ratio in
melilite slag is 3.6 and the values in excess with high alkali content must mean rising role of ferrous burden and coke fines formed
in shaft region. The need for corrective action arises in order to reopen coke chimney and increase deadman temperature (higher
coke Irsid 40/coke centre charging/lower iron production rate).
 6

SiO2/Al2O3 and alkalis (%)

SiO2/Al2O3 (III/BF1)
4 Alkalis
SiO2/Al2O3 (IV/BF1)
Alkalis
2 SiO2/Al2O3 (VI/BF1)
Alkalis

0
0 0.5 1 1.5 2 2.5
Distance from tuyere (m)

Figure 12 SiO2/Al2O3 ratio in drill core fines related to alkali content

Figure 13 shows distribution in CaO and MgO content in the drill core fines. Interest is concentrated on how BF temperature and
ferrous burden route affect chemical composition and increase amounts of fines.

30 9

CaO (III/BF1)
20 6 CaO (IV/BF1)

MgO (%)
CaO (%)

CaO (VI/BF1)
MgO (III/BF1)
MgO (IV/BF1)
10 3
MgO (VI/BF1)

0 0
0 0.5 1 1.5 2 2.5
Distance from tuyere (m)

Figure 13 Distribution in CaO and MgO contents in drill core fines

There can have potential to form tri- and dicalcium silicates from the gas interaction of lime and SiO2 at bird’s nest temperatures
(a). Gehlenite, Ca2Al2SiO7, forms from the diffusion of lime and solid mullite-type phase from coke (b) and åkermanite,
Ca2MgSi2O7, when merwinite and monticellite from ferrous burden melt together (c). Gradually there begin to occur molten
melilite droplets at solid solution of 28% gehlenite and 72% åkermanite (d). The progress of a condition, in which merwinite,
Ca3MgSi2O8, and monticellite, CaMgSiO4, fragments from ferrous burden were found in the centre of the furnace, means BF
periphery running, the centre getting colder and blocking up with iron and silicate fines (II/BF1 and V/BF1).

In order to be able to understand the accumulation process of fines in the deadman there is a need for comparisons of trace
element contents, those which are concentrated in ferrous burden, as vanadium titanium, nickel and chromium. Figure 14 shows
the vanadium distribution in drill core fines. As a conclusion can be drawn that ferrous burden load in excess through the furnace
centre have a connection with a decrease in temperature, the cohesion zone begins to move lower down and change to a V-shape.
However, considerable further research is required in order to determine the thermo-chemical mineral reactions.
 0.2
Iron routes Packing of iron
fines

0.15 II (BF1/5)
II (BF1/8)

V (%)
III (BF1)
0.1
IV (BF1/C)
V (BF2/C)
0.05 VI (BF1)
Packing of coke
fines
0
0 0.5 1 1.5 2 2.5 3
Distance from tuyere (m)

Figure 14 Distribution in vanadium content in drill core fines

Figure 15 shows the zinc distribution in drill core fines. During downward movement the bosh coke is in contact with wall skulls.
An increase in zinc and alkalis in bosh fines may be an indication of large peripheral gas flows and increased loosening of wall
skulls.

0.1
Effect of skulls
0.08
II (BF1/5)
II (BF1/8)
0.06
Zn (%)

III (BF1)
IV (BF1/C)
0.04
V (BF2/C)
VI (BF1)
0.02

0
0 0.5 1 1.5 2 2.5 3
Distance from tuyere (m)

Figure 15 Distribution in zinc content in drill core fines

CONCLUSIONS

The coke degradation taking place below the BF shaft is one part of the thermodynamically controlled blast furnace process. In
this respect traditional coke research and testing gives very little information and it is necessary to find new research methods. The
chemical analysis of tuyere drill core samples is a start in the study of causes and effects of deadman blockage.

The popularity of the NSC method for estimation of good coke quality passes a question about the positive effect of the acid ash
components on coke characterised by low CRI and high CSR. The negative effect of silica observed on increased coke
degradation and formation of fines below the blast furnace shaft have received very little attention. The fact raises that, despite
constant or higher CSR, coke degradation increases at tuyere level, if the ash content of the coke exceeds 11% and SiO2/Al2O3
ratio over 2.2. The Irsid 40 and Irsid 10 values arise the pronounced role in estimation of the sensitivity of the coke to break down
in blast furnace.

REFERENCES

1. Gornostayev, S., Kerkkonen, O. and Härkki, J.,”Importance of Mineralogical Data for Influencing Properties of Coke: a
Reference of SiO2 Polymorps”, Iron and Steel Research International, 11, Vol. 77 (2006), pp 770–773.

2. Gornostayev, S. and Härkki, J.,”Mineral matter crystallization and crack formation in tuyere coke”, Fuel 85, (2006), pp.
1047–1051.

3. Gornostayev, S., Kerkkonen, O. and Härkki, J.,”Occurrence and composition of some mineral phases in the tuyere coke”, ISIJ
International, Vol. 45 (2005), No. 1, pp. 1–7.