DISCUSSIONS

In general, all blast furnace feed materials require some form of processing before
being deemed suitable for blast furnace needs.Fine and ultra-fine ferrous ores must
first be agglomerated to produce sinter or pellets respectively. Lump ore may be
charged directly to a blast furnace but only after it has been suitably sized and
screened to remove over and undersize material. Lump ore, however, usually
comprises a minor portion of the total ferrous feed. Coal cannot be directly charged
via the furnace top, it must first be transformed to coke.This in turn has an influence
on the VIU of the parent coals used to make that coke.Internally the blast furnace is
considered to consist of five discrete zones, through which all furnace gases or
liquids must pass. The location, shape and extent of each zone is influenced by the
properties of the material layers (relative thickness, etc.) and by the properties of the
materials themselves. These factors interact to determine the flow and distribution of
gases within the furnace.

Based on the simulation that we did, at first,we obtained 5 warnings that prevent
us from getting the final result that we must solved.The first warning that we get was
excess amount of revert.So, we decreased the value to 100 for a stable
process.Next,the warning is a sign from lower amount of coke rate in the furnace
which we increase the amount for coke 1,coke 2 and coke 3 to 6000 each to increase
the coke rate. Furthermore, the fuel ratio for the 3 coal need a correction for the
furnace to worked properly which were adjusted to 100 for coal 1, 1400 for coal 2 and
2000 for coal 3.Oxygen promotes in the furnace is really an important way to get a
good combustion process. However, we tend to set up oxygen and other gas to a
lower percentage value . We change the value for oxygen to 3%, Hydrogen gas to 4%,
Carbon to methane ratio to 1% and the direct reduction rate to 45% which fixed this
problem.The last warning was our slag basicity was not included between range of 1.0
- 1.2 for the production.Then we fixed the value up.
 However, there still some things that we need to fix which exist in the charging
rates.The amount of acidic ore and the amount of acidic flux are increased while the
amount of basic ore and the amount of basic flux are decreased.The amount of flux
for limestone,dolomite,silica and olivine were increased to 2000,2400,2200 and 100
respectively.Unfortunately after we obtained first result, we still got 2 defects to be
fixed which were heat loss error prior to higher than 3% which is 6.74% and mass
lose error prior to higher than 2%(2.90%) thatt needed to be fixed. We lowered them
down by adjusting the hot blast properties.We change the temperature to 1150 ‘C ,
temperature drop to 45’C, pressure to 130kPa and humidity to 12.5 g/Nm.

Then, we finally get the result for the charging operation . After adjusting all the
error that we get ,we can succesfully determined each rate process. The coke rate that
stable for our composition is 405.91kg/t HM while for the coal rate is 101.13kg/t HM
and for the fuel rate is 507.04kg/t HM. For additional information, Iron content in the
ores is 59.79%, the energy utilization coefficient is 88.83%, carbon energy utilization
coefficient is 67.91% and the blast furnace utilization coefficient is 3.04.All of this are
very good and making our process stable.Lastly, the total cost are 462.98$/ t HM.