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CHAPTER 3 :
IRON AND STEEL PRODUCTION
Mechanical Engineering Department
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
Types of Iron Ore 1
Characteristics of Iron Ore 2
Iron Production Process 3
Steel Production Process 4
Iron is an element in the periodic table that has the symbol Fe and atomic number 26
metallic iron is produced from iron ore and rare elements found in free
Iron is the main and most abundant metal use
physical properties can be modified
price is cheap and easily available
most of the steel used was not in a pure
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
rocks that contain minerals of iron and other elements
composed of elements or compounds such as oxides, sulfides, sulfur, silicon, etc.
have different color
is the main ingredient in the production of pig iron
It was not in its pure form
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
have 40% - 65% iron content
is the highest of all iron ore is found
black to reddish brown
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
has 72.4% iron content
available in the form of land or a brick
have magnetic properties
blackish color
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
iron content of 50% and 50% sulfur
color is golden
found in crystal form
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
containing iron sebayak 20% - 55% and a water content of 40%
yellow color is brown, but when the water is removed it will change the color of haematite ore
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
have 25% - 30% iron content
color reddish or blackish
obtained in the form of bricks
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
iron content of less than 30% and is otherwise carbon and phosphorus content
Color gray ore
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
has a sulfur content of 50%
golden
obtained in the form of bricks
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
with 50% silicon content
can be divided into several types, namely kamosite, stillprunit, gururite and minnesotite
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
iron content of 30%
yellowish brown
can be classified according to the type of `gauge 'which existed as to whether` gauge that is rich in silica-rich or calcium oxide (CaO)
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
1. grade
- Contains as much iron oxide
2. density
- Not too heavy or too fragile.
3. genuineness
- Have the lowest content of foreign material may
4. uniformity
- Have a uniform composition of the group to another group
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
Step 1 : Concentration
Step 2 : Calcination
Step 3 : Smelting
The ore is crushed in crushers and is broken to small pieces. It is concentrated with gravity separation process in which it is washed with water to remove clay, sand, etc.
The ore is then heated in absence of air (calcined). This results in decomposition of carbonates into oxides and then ferrous oxide is converted into Ferric Oxide.
The concentrated ore is mixed with calculated quantity of coke, limestone and the mixture is put in the Blast Furnace from top.
322
23
COFe2OFeO4
COFeOFeCO
Blast furnace consists of a vertical steel shell ~100 ft
high & ~ 21 ft dia and lined with refractory material.
It has a charging arrangement (Bell & Cone) at the top.
Raw material is charged by a skip car through this
charging mechanism into the blast furnace.
It has a means of running off Pig iron & Slag at the
bottom.
Air is blown in near the bottom of the furnace. This
forced draught increases the speed of combustion &
maintains the necessary high temperature.
Cooling water is circulated around the Bosh area in
order to protect the furnace from high temp.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
raw material brought to the top of the furnace by car penangkut
it is inserted into the furnace through the distributor moves and through the use of a bell
This bell function for controlling the gas load loss
continuous hot air sprayed through a number of openings called `TUYER '
boiler used to heat the air up to 1100 C.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
air cooled and hot gas flow repeated in the opposite direction through the boiler
to supply continuous hot spray, each boiler furnaces have some work on a rotational basis
iron is removed from the furnace every 2 hours
molten iron and prop separately removed through a hole in the bottom of filter
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
Iron ore + coke + limestone + air
iron + slag + gas
carbon in coke combustion with oxygen in the air spray
reduction of iron oxide to
flush `gauge iron ore and ash with limestone.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
capital and operating costs are high
regulation of iron composition is relatively weak
small furnace that uses coke is not efficient
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
To produce one ton of pig iron, we need raw materials as follows:
2 tone iron ore+ 1 tone coke+ 1/2 tone limestone
1 tone iron
* Raw materials must be added all at once
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
used for smelting iron ore to make pig iron.
pig iron containing 93% pure iron, 3% - 5% carbon, silica, sulfur, phosphorus and manganese.
main ingredients for cast iron, wrought iron and steel.
props used for road and building blocks.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
In the beginning, it is IRON ...
Then, it became IRON Chartered ...
... finally, STEEL
is a very valuable metal
most types of metal and widely used
produced through the oxidation process that reduces the amount of carbon, silicon, manganese, and sulfur forforus in a mixture of molten pig iron and steel scrap
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
1. In the field of construction and building bridges .....
2. In the automotive sector ....
3. For daily use: cans, pots, containers, etc.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
it uses pure oxygen
can move horizontally and vertically
while leaning state, furnace filled with molten iron and scrap iron 30%
during the vertical, boost oxygen with high-speed fluid is directed kepermukaan content
Oxygen is cooled with water
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
Some carbon is converted into gaseous oxides
An old result when the oxide reacts with limestone
furnace is tilted to the horizontal position to produce mild steel melting
furnace reversed to remove the prop
able to produce high quality steel quickly of 80 tonnes per hour
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
have a high capacity and easy to operate
low oxygen consumption rate
appropriate to increase the grade of steel
using the supplied natural oxygen jet
produce 120 tons of steel in the first 4 hours.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
has a curve shape as a convex cylinder
made of steel and coated with heat-resistant brick
The cap can be removed and there is a three-way, or opening where carbon electrodes can be moved freely
use coolant through channels outside the furnace copper
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
1. charging
charge materials containing steel scrap, pig iron, iron oxide and lime added to the furnace
electric current is passed to the carbon electrodes for electric arc supply
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
2. smelting
electric arc with high heat will melt the charge material oxygenated
silicon, and phosphorus mangganes start oxidized and mixed with lime to form the basic prop
no metal is lost as carbon electrodes burn
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
3. isolation
phosphorus transfer depends on the basic prop in calcium oxide
lime, iron oxide flourospar and mixed to form a fulcrum that react with impurities
composed of steel required to developFeS + CaO + C CaS + Fe + CO
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
4. closure
Oxidized steel using aluminum, Ferro-Silicon or Ferro-Mangganes
To take steel, prop knitted or poured from the surface first and then removed or drained through the hole / channel exit by tilting furnace
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
sulfur transfer or change is appropriate.
combustion can be controlled and managed effectively.
no oxidizing gas to produce high quality steel.
temperature can be precisely controlled.
addition of alloy elements can be made correctly.
furnaces are free from dirt and smoke.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION
1. Briefly explain THREE (3) types of iron ore on the surface of the earth.
2. Mention THREE (3) types of furnaces to produce the production.
i. Iron.
ii. Steel.
3. What is the charge material is included in the following furnaces:
i. Bagas furnace.
ii. Electric arc furnace.
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION