Custom-Built Softening and Melting Furnace for Iron Ore Testing

Client Objective

To simulate high-temperature conditions similar to those in a blast furnace in order to test the softening and melting behavior of iron ore pellets, lumps, and sinters. The system needed to comply with IS 9660:2001 standards and provide precise, repeatable data under controlled mechanical load and gas atmospheres.

Our Solution

Ants Innovations developed a customized Softening and Melting Furnace designed specifically to evaluate the behavior of iron-bearing materials under load and thermal reduction. The system was engineered to replicate the conditions found in blast furnaces, enabling users to measure critical parameters such as softening start and finish temperatures, pressure drop, shrinkage, and fusion range.

Advanced Heating System

Capable of reaching temperatures up to 1600°C with programmable, non-linear heating profiles. The heating rate could be gradually reduced during the test, mimicking real-world blast furnace conditions.

Test Chamber Configuration

The furnace includes a uniform heating zone (55 mm diameter × 40 mm height) that houses a cylindrical crucible made of steel or graphite. A constant compressive load of 2 kg/cm² is applied using a hydraulic press to simulate blast furnace burden pressure.

Atmosphere Control

The system operates under a neutral or reducing atmosphere using purified nitrogen or a gas mixture of 30% CO and 70% N₂, depending on the testing method selected. Stainless steel tubes ensure controlled gas flow during testing.

Displacement Measurement System (LVDT-Based)

To track the sample’s shrinkage during softening, an LVDT sensor measures displacement in real time. This enables precise identification of softening and melt-down points, which is essential for evaluating the behavior of iron ore materials.

Dual Testing Approaches

The system supports both traditional shrinkage measurement as well as pressure drop-based evaluation. The latter involves packing the test material between coke and alumina balls to simulate actual blast furnace charging conditions.

Automated Controls and Data Logging

Equipped with PLC-based automation and HMI for real-time monitoring of heating curves, displacement, and system status. The system supports SCADA integration for remote access and long-duration data acquisition.

Safety and Emission Controls

Includes over-temperature protection, emergency shutdown, and exhaust systems to manage emissions safely and ensure regulatory compliance.

Outcome

The delivered furnace system enabled the client to conduct highly accurate simulations of blast furnace thermal and mechanical conditions. It provided critical insights into the softening and melting characteristics of iron ore inputs, helping improve burden design, process optimization, and raw material selection for efficient blast furnace operations.

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