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7/29/2019 116364638 Iron and Steel Manufacturing Process Ppt
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Iron And Steel Manufacturing
Process
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Four steps:
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Iron Making Process
producing iron from iron ore
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Methods in iron Making Process
1. Coke-oven-Sinter-BF route
2. Direct Reduction Technique3. Smelting Reduction Technologies
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Coke-oven-Sinter-BF route
used by integrated steel plants that
produce steel from iron ore.
In this process, the iron ore is first
subjected to a sintering process.
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Sintering Process
is the technology for agglomeration
of iron ore fines into useful BlastFurnace burden material.
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The treated iron from the sintering plant is fedin to the Blast furnace along with coke. The
blast furnace basically does the function of
converting iron oxide in to liquid iron. Coke is
used as a reducing agent as well as fuel. The
output from the furnace is the pure iron in
molten stage, which is called hot metal.
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The hot metal output from the Blast
furnace is either directly fed in to the
Basic Oxygen Furnace or used for
producing pig iron.
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Direct Reduction Technique
an alternative to the Blast furnace
technique.
This technique produces 97.0
percent pure iron, which is called,
solid Sponge Iron.
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Smelting Reduction Technologies
In this process, the hot metal (liquid
iron) is produced from iron ore in two
steps. Ores are partly reduced in the
first step and then final reduction and
melting, takes place in the second
stage.
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Corex Technique
Here coal is directly used in a melter
gesifier as an energy carrier & reducingagent, thereby eliminating the need for
a Blast Furnace, Sinter Plant & Coke
Ovens
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Other techniques used:
- Hismelt
- Ausmelt
- Romelt- Plasmasmelt
- Iron Smelting Reduction (DIOS)
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Steel Making Process
producing steel from iron
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Types of techniques:
1. Basic Oxygen Furnace (BOF) type
2. Electric arc furnace (EAF) type.
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Basic Oxygen Furnace (BOF)
used for producing steel from the
refined iron.
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Basic Oxygen Furnace (BOF)
Hot metal from the Blast furnace, which is a
pear shaped furnace or reduced iron from the
smelting plant is fed in to the Basic Oxygen
Furnace (BOF) after pre-treatment to removeundesired elements like sulfur, silicon or
phosphorous.
Molten Steel in liquid form is obtained.
Impurities go out in gaseous form and as slag.
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Electric arc furnace (EAF)
Steel scrap is melted using heat generated
with the aid of an electric arc produced by
graphite electrodes.
In this technique, the output is crude steel
which is used in eitheringots or fed in the
continuous casting process cycle.
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Ingot
Molten steel cast in vertical cast
iron moulds intended for rollingafter heating in two stages i.e. in a
primary mill and then in a finishing
mill.
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Continuous Steel Casting process
liquid steel is directly cast into semi-
finished products, which eliminates the
need for primary rolling of ingots.
The crude steel or liquid steel is poured
into a reciprocating refractory-lined
receptacle, called a Tundish.
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Below the Tundish are water-cooled copper
moulds of desired size.
The steel solidified in the moulds is slowly
pulled out to produce an "endless" strand,which is gas-cut to desired lengths.
This steel is called semi-finished steel. Thesemi-finished steel is fed in to re-rolling
mills to get finished steel products.
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Finished steel products are
classified in to two types:
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Finished Carbon Steel
- steel that has properties made up
mostly of the element carbon, andwhich relies on the carbon content
for structure.
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Classifications:
1. Long products
2. Flat products
3. Other carbon steel product
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Long products
they are used used in the
construction and engineering industryand, to some extent, in the
manufacturing sector.
(e.g. rods, channels, angles and otherstructural materials)
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Flat products
They may be hot-rolled, cold-rolled or
galvanized and find use mainly inautomobile, shipbuilding and the
white goods/consumer durables
sectors.
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Finished Alloy Steel
Alloy steel is defined as a material
containing Iron, carbon (less than 2.0
percent), Silicon, Manganese plus Alloy
elements like Chromium, Vanadium,Molybdenium, Tungsten, Nickel, Lead,
Naboium, Copper etc.
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Stainless steel is alloy steel that contains
more than 10.0 percent chromium, with or
without other alloying elements. Stainless
steel has special properties like high level ofcorrosion resistance and the ability to
maintain its strength at high temperatures.
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