116364638 iron and steel manufacturing process ppt

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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116364638 iron and steel manufacturing process ppt

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