Steel Making Using Open Hearth Furnace-1
Steel Making Using Open Hearth Furnace-1
Steel Making Using Open Hearth Furnace-1
Steel making using open hearth furnaces is a process that has been used for over a century
and has contributed significantly to the growth and development of the steel industry. This
method involves the conversion of raw materials, such as iron ore and scrap metal, into high-
quality steel through a combination of heating, refining, and alloying.
• The furnace consists of a shallow bath capable of holding from 60 to 300 tons of metal at a
time.
• There is back wall, doors in the front wall and a roof over the top.
• On each side of bath is a set of two heating chambers one is to pre-heat air and other to
pre-heat coal produced gas.
• To charge a basic furnace calcined dolomite or sand is thrown over the bottom and side walls.
• After about two hours when scrap has begun to melt pig iron is added.
• After this melting period begins.
b. Firing and Heating: Once the charge is in place, the furnace is fired, and the temperature is
gradually raised. The heat is provided by burning fuel, such as coal or natural gas, in a
combustion chamber located beneath the hearth.
c. Regenerative System: One of the key features of the open hearth furnace is its regenerative
system. The waste gases produced during combustion are directed through checker work
chambers, which absorb heat. The direction of the gases is then reversed periodically,
transferring the stored heat to the incoming air and fuel, significantly improving energy
efficiency.
d. Melting and Refining: As the temperature increases, the charge materials melt and undergo a
refining process. The impurities in the pig iron are oxidized and removed, and the desired
alloying elements are added to achieve the desired steel composition.
e. Tapping and Casting: Once the steel has reached the desired composition and temperature, it
is tapped from the furnace and cast into molds or further processed for various applications.
Tapping
• Heat is supplied to the furnace by burning the mixture of gas and air.
• Melting may takes place in three hours depending upon the nature and size of the charge.
• During this time some of the carbon and most manganese and silicon has removed by
oxidation.
• These impurities are removed by adding limestone millscale and also by the oxidizing action of
the flame.
De-slagging
Slag is removed in two stages;
• Some of the slag flows out of the notch during the early part of the process.
Steel Castings
• Steel castings are used when cast irons cannot deliver enough strength or shock resistance.
• Examples of items that are steel castings include: hydroelectric turbine, wheels, gears, railroad
truck, frames, valve bodies, pump casings, mining machinery, marine equipment, and engine
parts.
Uses
• Steel produced by open hearth is either of low (0.15- 0.3% carbon) or medium (0.3-0.7%
carbon).
• Low (0.15-0.3% carbon) steel used in boilers plates, bridge work, structural work etc.
• Medium (0.3-0.7% carbon) used in axels, hammers, springs and dies.
b. Flexibility: Unlike some other steelmaking methods, the open hearth furnace can
accommodate different types of charge materials, including pig iron, scrap metal, and various
additives.
c. Waste Heat Recovery: The regenerative system employed in the open hearth furnace
significantly improves energy efficiency by harnessing waste heat and reducing fuel
consumption.
d. Quality control: With the ability to fine-tune the chemical composition of the steel, open
hearth furnace technology allows for the production of specific grades and tailored alloys,
meeting the diverse needs of various industries.
c. Efficiency: Although open hearth furnaces have lower thermal efficiency compared to other
methods, they make up for it with the ability to handle large batches of raw materials.
Additionally, the continuous refining process ensures uniform quality throughout the production
cycle.
b. Longevity: The open hearth furnace was the dominant steelmaking method for much of the
20th century, contributing to the construction of iconic structures and the development of
infrastructure worldwide.
c. Technological Progression: The advancements made in open hearth furnace technology paved
the way for subsequent steelmaking processes, such as the basic oxygen furnace (BOF) and
electric arc furnace (EAF).
The open-hearth furnace played a crucial role in the steel industry during the 20th century, but
its dominance gradually declined in the latter half of the century. Factors contributing to its
decline include:
1. Emergence of Electric Arc Furnaces: Electric arc furnaces (EAFs) emerged as a more
energy-efficient and environmentally friendly alternative.
2. Adoption of Basic Oxygen Furnace (BOF) Technology: The BOF process offered faster
production and lower labor requirements, making it more competitive.
By the 1980s, open-hearth furnaces were largely replaced by EAFs and BOFs, and their
production significantly diminished. However, the open-hearth process left an indelible
mark on the steel industry, paving the way for advancements in steelmaking technology.
4.0 Conclusion:
In conclusion, the open hearth furnace stands as a testament to human ingenuity and
engineering prowess. While it has been largely replaced by more efficient and economical
steelmaking methods, we must recognize and appreciate its historical significance and the
crucial role it played in shaping our modern world. The principles and lessons learned from the
open hearth furnace continue to influence and guide advancements in steel production. As we
embrace new technologies, let us not forget the foundations upon which they were built—the
time-honored process of steel making using an open hearth furnace. Thank you.
5.0REFERENCE
1. Rosenhain, W., & Whiteley, A. H. (1928). The Open Hearth Steel Furnace: Its
Construction, Operation, and Maintenance. Cambridge University Press.
2. Rostoker, W., & Bronson, B. (1990). Pre-Industrial Iron: Its Technology and Ethnology.
Brill.
3. Kenneth, W. (2006). A History of Steel: From Iron to the Bessemer Process. Facts On File.
4. Warren, K. (1990). The American Steel Industry: A Historical Perspective and Future
Prospects. Springer.