Blast Furnace Recipe
A no-oven, high-temperature cooking method that turns iron ore into pig iron in under two hours. Bring industrial cooking to your own foundry bench with this guide that combines iron smelting know-how with kitchen-style flair.
Ingredients
- 100 kg iron ore (hematite concentrate, ~65% Fe) crushed to <10 mm
- 50 kg metallurgical coke or anthracite/charcoal as a simple substitute
- 25 kg limestone (flux; dried at 105 °C for 1 hour) to remove moisture
- 10 m³ pre-heated air (blown in at 1.8–2.2 bar) via a hot-blast stove
- 200 kWh electricity for blower and starter torch
- 5 kg silica sand refractory lining top-up, optional brand: Harbison-Walker
- Safety gear: heat-resistant gloves, face shield, steel-toe boots
Instructions
- Preheat your furnace hearth to around 1,500 °C and light an oxy-fuel torch or electric starter for 15 minutes.
- Layer coke, ore, and limestone in alternating patterns until half the materials are used.
- Set air pressure to 2 bar and temperature to 800°C. Add the rest of the mix when the blast reaches a steady roar.
- Keep the temperature at 1,800°C for at least 45 minutes until reduction reactions are in full swing.
- Tap the molten iron into pre-heated pig molds using long tongs and stand back for safety.
- Let the pigs cool for 30 minutes, then break away the slag cap and store in a dry area.
Notes
Choose low-sulfur ore for better results. Store flux in a dry bin to avoid clumping.
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