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Hot blast allowed the use of anthracite in iron smelting. It also allowed use of lower quality coal because less fuel meant proportionately less sulfur and ash. [11]At the time the process was invented, good coking coal was only available in sufficient quantities in Great Britain and western Germany, [12] so iron furnaces in the US were using charcoal.
A metallurgical furnace, often simply referred to as a furnace when the context is known, is an industrial furnace used to heat, melt, or otherwise process metals. Furnaces have been a central piece of equipment throughout the history of metallurgy ; processing metals with heat is even its own engineering specialty known as pyrometallurgy .
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The tuyeres are used to implement a hot blast, which is used to increase the efficiency of the blast furnace. The hot blast is directed into the furnace through water-cooled copper nozzles called tuyeres near the base. The hot blast temperature can be from 900 to 1,300 °C (1,650 to 2,370 °F) depending on the stove design and condition.
The movement away from charcoal in US iron smelting began in 1827, when a puddling furnace in Phoenixville, Pennsylvania started using anthracite coal. Blast furnaces continued to use only charcoal until about 1840, when coke from coal started replacing charcoal as the fuel and reducing agent. [5]
For blast furnaces, direct reduction corresponds to the reduction of oxides by the carbon in the coke. However, in practice, direct reduction only plays a significant role in the final stage of iron reduction in a blast furnace, by helping to reduce wustite (FeO) to iron. In this case, the chemical reaction can be trivially described as follows ...
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