Blast furnace

A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. Blast refers to the combustion air being 'forced' or supplied above atmospheric pressure. In a blast furnace, fuel (coke), ores, and flux (limestone) are continuously supplied through the top of the furnace, while a hot blast of air (sometimes with oxygen enrichment) is blown into the lower section of the furnace through a series of pipes called tuyeres, so that the chemical reactions take place throughout the furnace as the material falls downward. The end products are usually molten metal and slag phases tapped from the bottom, and waste gases (flue gas) exiting from the top of the furnace. The downward flow of the ore and flux in contact with an upflow of hot, carbon monoxide-rich combustion gases is a countercurrent exchange and chemical reaction process. In contrast, air furnaces (such as reverberatory furnaces) are naturally aspirated, usually by the convection of hot gases in a chimney flue. According to this broad definition, bloomeries for iron, blowing houses for tin, and smelt mills for lead would be classified as blast furnaces. However, the term has usually been limited to those used for smelting iron ore to produce pig iron, an intermediate material used in the production of commercial iron and steel, and the shaft furnaces used in combination with sinter plants in base metals smelting. Cast iron has been found in China dating to the 5th century BC, but the earliest extant blast furnaces in China date to the 1st century AD and in the West from the High Middle Ages. They spread from the region around Namur in Wallonia (Belgium) in the late 15th century, being introduced to England in 1491. The fuel used in these was invariably charcoal. The successful substitution of coke for charcoal is widely attributed to English inventor Abraham Darby in 1709. The efficiency of the process was further enhanced by the practice of preheating the combustion air (hot blast), patented by Scottish inventor James Beaumont Neilson in 1828. Archaeological evidence shows that bloomeries appeared in China around 800 BC. Originally it was thought that the Chinese started casting iron right from the beginning, but this theory has since been debunked by the discovery of 'more than ten' iron digging implements found in the tomb of Duke Jing of Qin (d. 537 BC), whose tomb is located in Fengxiang County, Shaanxi (a museum exists on the site today). There is however no evidence of the bloomery in China after the appearance of the blast furnace and cast iron. In China blast furnaces produced cast iron, which was then either converted into finished implements in a cupola furnace, or turned into wrought iron in a fining hearth. Although cast iron farm tools and weapons were widespread in China by the 5th century BC, employing workforces of over 200 men in iron smelters from the 3rd century onward, the earliest extant blast furnaces were built date to the Han Dynasty in the 1st century AD. These early furnaces had clay walls and used phosphorus-containing minerals as a flux. Chinese blast furnaces ranged from around two to ten meters in height, depending on the region. The largest ones were found in modern Sichuan and Guangdong, while the 'dwarf' blast furnaces were found in Dabieshan. In construction, they are both around the same level of technological sophistication The effectiveness of the Chinese blast furnace was enhanced during this period by the engineer Du Shi (c. AD 31), who applied the power of waterwheels to piston-bellows in forging cast iron. Donald Wagner suggests that early blast furnace and cast iron production evolved from furnaces used to melt bronze. Certainly, though, iron was essential to military success by the time the State of Qin had unified China (221 BC). Usage of the blast and cupola furnace remained widespread during the Song and Tang Dynasties. By the 11th century, the Song Dynasty Chinese iron industry made a switch of resources from charcoal to coke in casting iron and steel, sparing thousands of acres of woodland from felling. This may have happened as early as the 4th century AD. The primary advantage of the early blast furnace was in large scale production and making iron implements more readily available to peasants. Cast iron is more brittle than wrought iron or steel, which required additional fining and then cementation or co-fusion to produce, but for menial activities such as farming it sufficed. By using the blast furnace, it was possible to produce larger quantities of tools such as ploughshares more efficiently than the bloomery. In areas where quality was important, such as warfare, wrought iron and steel were preferred. Nearly all Han period weapons are made of wrought iron or steel, with the exception of axe-heads, of which many are made of cast iron.