Flow of Iron in Blast Furnace Hearth

The theoretical and experimental studies have been done to clarify the hearth flow of iron and slag. The results of dissections show that the hearth can be treated as a packed bed of coke hav- ing good permeability with a coke-free layer at the bottom of the hearth. 3-dimensional numerical calculations of hearth flow with and without a coke-free layer are carried out, and the results are assured by a water model simulation. The influences of a coke-free layer on the iron flow and the discharge route of iron and slag are examined. The 3-dimensional flow pattern can be represented simply by the travelling time, which depends on characteristically the profile of coke-free layer and the quantity of iron in the hearth. Those flow parameters could be obtained by the results of radioisotope tracer test ( Co for iron flow, and Sc for slag flow) at several furnaces. As a result, it is found that the coke-free layer repeats the cycle of appearance and disappearance at several-month intervals. This cycle corres- ponds to large temperature fluctuation at the bottom of hearth. The relation between iron flow and skull (solidified iron, coke and deposited graphite mixed layer) on the hearth brick was studied by the model experiment and the thermal analysis based on the indications of thermocouples installed in the bottom of the hearth. If a thin coke-free layer is formed on the skull, a fast iron flow is generated in the layer, and melts away the skull. The growth and melting of skull produces the fluctuation of thermal load on a bottom brick, causing brick Damage.