A Term paper on :

STEEL MAKING USING OPEN HEARTH FURNANCE

PRESENTED BY ;

Ahmed Khalid Dango 17/46471u/2

Bamigboye victor Adeboye 17/46984u/2
Muhammad Sani Abubakar 17/46417u/2
Okonkwo Chibuzor Emmanuel 17/47413u/2
Farouq Abdullahi Umar 17/47547u/2
Aliyu Isiaka 17/47794u/2
Sa’ad Hassan 17/48971D/2
Victory Musa Wetpan 17/49224u/2
Usman Suleiman 17/46394u/2
Ismail Ibrahim Jagamu. 18/53290D/2
 STEEL MAKING USING OPEN HEARTH FURNACE
1.0: INTRODUCTION

1.1 Understanding the Open Hearth Furnace:

The open hearth furnace is a type of reverberatory furnace that revolutionized steel making
during the late 19th and early 20th centuries. It is a large, brick-lined chamber where steel is
produced by melting a mixture of pig iron, scrap metal, and fluxes. The distinguishing feature of
the open hearth furnace is its regenerative system, which utilizes waste heat recovery to
improve energy efficiency.

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.

1.2 History Of Open Hearth Furnace

1. William Siemens developed the open hearth furnace by preheating the incoming air .
2. Pierre martin was responsible for dilution of pig iron with scrap
3. By combining both Siemens-martin open hearth process was developed

1.3 Construction Of An Open Hearth Furnace

• Furnace can either tilting or fixed.

• 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.

• These chambers are filled with open chequered bricks.

 • At each end of the hearth openings are provided. Openings at one end is to allow the
passage of heated gas and air which burns with flame directed down on the metal.
The second opening allows the burned gases to escape to the chimney via regenerators.

• These regenerators are a series of chequered brickwork heating chambers.

• Capacity is 10 to 300 tons.

1.4 The Process:

a. Charging the Furnace: The charge materials, including pig iron, scrap metal, and fluxes, are
carefully measured and loaded into the furnace. The proportions are determined based on the
desired steel composition.

Charging The Furnace

• Charging can be in cold and liquid state.

• The charge is pig iron, molten or solid iron and scrap.

• Limestone and iron ore added as required.

• It is charged by mechanical charging machine.

• To charge a basic furnace calcined dolomite or sand is thrown over the bottom and side walls.

• This operation is called fettling(repairing the lining).

• After fettling hearth is heated about 1500c.

• Limestone on bottom is followed by iron ore then iron and scrap.

• 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

• Tapping is removal of molten product from the furnace.

• When steel is judged for desired carbon content it is than tapped.

• At this point slag float on the steel and it is removed.

 Working Principle Of The Open Hearth Furnace

• 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.

• In boil stage last of carbon is removed.

When melting is completed certain elements are added to remove remaining impurities like, Si,
S, and P.

De-slagging
Slag is removed in two stages;
• Some of the slag flows out of the notch during the early part of the process.

• Remainder is separated by means of special ladle.

• When steel is poured into ingot molds retain the slag

Steel Castings

• Steel casting is a specialized form of casting involving various types of steel.

• 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).

• Alloy steel is also produced by this process.

• 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.

2.0 Advantages of Open Hearth Furnace:

a. Versatility: The open hearth furnace allows for the production of a wide range of steel grades,
making it highly versatile for various applications. They offer great flexibility in terms of input
materials. They can use both iron ore and scrap metal, enabling cost-effective recycling and
reducing the reliance on primary resources.

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.

2.1 Disadvantages of Open Hearth Furnace

a. Energy Consumption :The open-hearth process is relatively energy-intensive compared to

more modern steelmaking methods.
B. Labor Requirements :The open-hearth process requires significant manual labor for charging,
tapping, and slag removal.
c. Environmental Impact: The open-hearth process generates emissions and can have
environmental impacts if not properly controlled.

3.0 Historical Significance:

a. Industrial Revolution: The open hearth furnace played a pivotal role in the Industrial
Revolution, meeting the increasing demand for steel and fueling rapid industrialization around
the world.

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).

3.1 Decline and Replacement of Open Hearth Furnace

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.