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Exercises · 6.7

Q.Write down the reactions taking place in different zones in the blast furnace during the extraction of iron.

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Step 1 – Overall setup

The blast furnace is charged from the top with a mixture of roasted iron ore (mainly haematite, Fe2O3Fe_2O_3), coke, and limestone (CaCO3CaCO_3). A blast of hot air is blown in near the bottom, through nozzles called tuyeres. As the charge descends, it passes through zones of progressively increasing temperature (roughly 500 K near the top to over 2000 K near the bottom), and different reactions occur in each zone.

Step 2 – Combustion zone (near the tuyeres, hottest, ~2170 K)

Coke burns in the blast of hot air:

C+O2→CO2(strongly exothermic, generates the furnace heat)C + O_2 \rightarrow CO_2 \qquad (\text{strongly exothermic, generates the furnace heat})

The CO2CO_2 formed then reacts with excess hot coke just above:

CO2+C→2COCO_2 + C \rightarrow 2CO

This carbon monoxide is the main reducing agent that rises up through the furnace.

Step 3 – Reduction zone (upper/cooler region, ~500–800 K) — indirect reduction by CO

As CO rises into the cooler upper zones, it progressively reduces haematite:

3Fe2O3+CO→2Fe3O4+CO23Fe_2O_3 + CO \rightarrow 2Fe_3O_4 + CO_2

Fe3O4+4CO→3Fe+4CO2Fe_3O_4 + 4CO \rightarrow 3Fe + 4CO_2

(and partially, Fe2O3+CO→2FeO+CO2Fe_2O_3 + CO \rightarrow 2FeO + CO_2)

Step 4 – Middle zone (~900–1500 K) — limestone decomposition

Limestone charged along with the ore decomposes:

CaCO3→CaO+CO2CaCO_3 \rightarrow CaO + CO_2

Step 5 – Lower zone (~1500–1600 K) — direct reduction and slag formation

Any remaining FeO is reduced directly by carbon at this higher temperature:

FeO+C→Fe+COFeO + C \rightarrow Fe + CO

The lime (CaO) formed combines with silica gangue to form slag:

CaO+SiO2→CaSiO3 (slag)CaO + SiO_2 \rightarrow CaSiO_3 \ (\text{slag})

Step 6 – Collection …

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