chapter 3 - iron and steel production (1)

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


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


have 40% - 65% iron content

is the highest of all iron ore is found

black to reddish brown


has 72.4% iron content

available in the form of land or a brick

have magnetic properties

blackish color


iron content of 50% and 50% sulfur

color is golden

found in crystal form


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


have 25% - 30% iron content

color reddish or blackish

obtained in the form of bricks


iron content of less than 30% and is otherwise carbon and phosphorus content

Color gray ore


has a sulfur content of 50%

golden

obtained in the form of bricks


with 50% silicon content

can be divided into several types, namely kamosite, stillprunit, gururite and minnesotite


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)


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



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.


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.


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


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.


capital and operating costs are high

regulation of iron composition is relatively weak

small furnace that uses coke is not efficient


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


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.



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



1. In the field of construction and building bridges .....

2. In the automotive sector ....

3. For daily use: cans, pots, containers, etc.

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


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


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.


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


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


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


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


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


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.


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.


chapter 3 - iron and steel production (1)

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