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The specifics

Metallurgycal-economical and methodological specifics of the BFC application:

  • Technical-economicl evaluation (TE-price determination) of each burden material for agglomeration and for blast furnace, including injected fuels from tuyeres. Please see the Picture E below.
  • In addition to calculating parameters without optimization, BFC also has the following two options:
    • Calculating of burden optimization by the criterion
      the minimum cost of iron production”. Please see the Pic.O below.
    • Calculating of burden optimization by the criterion  
      the maximum quantity of iron production”.
  • Calculating main parameters of agglomeration production and chemical composition of the agglomerate according to the specified parameters for the blast furnace, with the possibility of calculating the agglomeration fuel consumption from the thermal balance of the agglomeration.
  • Calculating the consumption of coke for the blast furnace (the most important item of cost for the iron production) can be made except by “Index of direct reduction” (rd) and based on a specified “percent of coke reserve”, which is the percentage of excess coke relative to the Minimum possible consumption of coke. Please see the Pic.S below.
  • In addition to displaying important input and calculated data on the monitor and in the ‘pdf’ report, BFC also has the following features:
    • Create a detailed report in Excel for each calculation,
    • Create a comparative Excel spreadsheet with data from multiple calculations ,that in both cases allows the user to process and graphically display the data according to their needs.
  • BFC calculations are organized into projects and into ‘trilingual’ mode, with the possibility of languages expansion.
  • The BFC app contains the “BFC Project Example” with almost 90 completed and described calculations, many of them professionally useful and which the user can upload to their BFC projects.

 

Picture E – Table of example for calculating tehno-ekonomic price of iron materials

*Note – The global TE-price provides the total cost of iron production equal 293.04 $/t_iron, who is achieved with the reference material (for exampl, Carajas_fine ore with the market price of 90 $/t_dry) . In total costs there are and cost for burden component to achieving the setpoint of slag basicity.

**Note – The Complex TE-price provides a total iron production cost of $293.04/t_iron (achievable with the reference Carajas_fine ore). In addition to the costs of “The Global TE-price” case (see * Note), there are now costs for new burden materials, which corrects of deficiencies in the valued ore. These deficiencies can be an excess of harmful elements (alkalis, S, Zn, Pb, P, As, etc.) or a lack of useful ones (MgO, Mn). Also, the deficiency of the valued ore may be, for example, very small grains in fine or lump ore or verya acidic pellets, which can damage the refractory lining of the blast furnace. Therefore, additives (dolomite, manganese ore, bentonite,…) or pure ores (for example “Carajas fine”) enter the sinter or directly into the blast furnace. All this limits the consumption of the valued ore (col. 9 in the table above) and reduces its TE-price (col. 10), in order to compensate for the costs of purchasing components that correct its deficiencies.

Picture O – Table of example for optimization of costs iron production by burdens structure calculating – see ***Note

***Note – The data in the yellow fields and in the title “Setpoint data” are input. Based on them, data in blue fields and a minimum total production cost of 265.68 $/t iron were calculated. That cost is $27.36 less than $293.04, which is the minimum total cost of production with one, any, ferrous material and its TE price listed in the table (see **Note). The reduction in the cost of production of $27.36 is the result of the mutual compensation of the deficiencies of the materials.

 

If you save only $ 1 per ton of iron in this way (using the BFC app), the annual savings will be several million dollars.

Picture S – Relation od Index direct reduction and Coke consumption, in generally case and in calculation of BFC app for practical needs case

NOTE: In the case when coke consumption is calculated on the basis of an estimate of the value of the “Direct Reduction Index”, this estimate refers to about 50% of the total consumption of coke, ie 100 * (526-268.7)/526. However, when this calculation is made on the basis of the estimate of the value of “Percent of coke reserve”, then the estimate refers to about 18-23% of the total consumption of coke, ie 100 * 88.7/526. This means that in the first case, the possibility of incorrect assessment is 2-3 times higher.
The reason for this is that in the second case, the “Minimum possible coke consumption” is calculated in advance, which is generally about 77-82% of the total amount of coke. Also, in this case, it is not possible to calculate the total coke consumption less than the “Minimum possible value”, while in the first case it is possible