Gather raw materials: iron ore, coke, limestone (flux), air (blast), and optional recycled gases
Preheat and prepare the blast furnace: inspect lining, tuyeres, stoves, top charging system, and gas-cleaning equipment
Prepare coke: crush and size coke to suitable distribution
Prepare burden materials: screen and size iron ore; prepare limestone (flux) with suitable size
Load the furnace stack: charge alternating layers of ore, coke, and limestone through the top
Start the hot blast: deliver preheated air through the tuyeres to the lower furnace hearth
Maintain furnace operation: control burden rate, air flow, and blast temperature to sustain the combustion and reduction zones
Manage temperatures and reactions: regulate coke-to-ore ratio and flux rate to achieve proper slag formation and iron reduction
Collect molten products: drain and tap slag and molten iron at scheduled intervals
Quench and handle slag: route slag to processing or disposal
Route top gas: collect, cool, clean, and reuse or treat blast furnace gas
Monitor and adjust: track furnace pressure, gas composition, burden distribution, hearth condition, and tapping quality
Ensure safety and compliance: manage high-temperature operations, gas handling, dust control, and emergency shutdown procedures
Stop and cool down: cease charging, manage gas drawdown safely, and cool the furnace for maintenance or relining