Steel Making: Lecture 1 Introduction to the subject and review of Iron Making
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This document outlines the course plan for a steel making processes course. It includes topics that will be covered such as the various steelmaking methods like basic oxygen furnace and electric arc furnace. It also lists the textbook references and learning resources provided. The course will have lectures, assignments, simulations, midterm and final exams. Students will learn about the raw materials, chemistry, equipment and processes involved in steel production.
Steel Making: Lecture 1 Introduction to the subject and review of Iron Making
- 1. Lecture No 1 07-01-2013 Course Title: MY-301: Steel Making Processes Course Teacher: Muhammad Ali Siddiqui, Lecturer Academic Session: Spring Semester (2013) Batch: 2010-11 Course Plan TOPICS NO. OF PERIODS Introduction, Difference between iron and steel making processes. An outline of various methods of steelmaking - Physical chemistry of steel making process Raw materials for steel making Process;Acid open hearth and basic open hearth processes. Oxygen Enrichment of fuel Operation, control of composition and different slag practices. Principles of operation under different slag practices for steelmaking by Electric Arc furnace and Induction furnace. Rapid steel making, Basic oxygen furnaces. Acid Bessemer. Basic Bessemer. Side blown convertor. L.D. convertor, Kaldo Rotor- Bottom blown and combined blown processes ofsteel making Mid Test Deoxidation by Si. Al- Mn etc., Comparison of deoxidising effects of various deoxidisers. Deoxidation by complex deoxidisers. Vacuum degassing of steels. Ladle Metallurgy. Conceptof clean steel.
- 2. Lecture No 1 07-01-2013 Introduction to secondary steel making. Some modern developments in steel making like ESR VOD and AOD process Pre-treatment of steels. Ingot solidification. Killed, semi killed. Rimmed and capped steels. Ingot defects, their identification and remedial actions Continuous casting of steel. Low, medium and high carbonsteels. Alloy Steels Toolsteels and stainless steels. Applications of Computers in steel making processes Manganese steels Free cutting steel Basis of designing of Steels. Final Test Total 45
- 3. Lecture No 1 07-01-2013 Sessional Marks Distribution Activity in Spring Semester Marks Distribution Attendance No Marks Total Test = 02 (Each test of 5 No’s) 10 No's. Problems Assignment Assign During lectures 5 No’s. Working on EAF,BOS,CC Simulation (Minimum Practice = 30 times per simulation), False HEAT does not included (www.steeluniversity.org) 5 + 5 + 5 = 15 No’s. Total 30 Total Marks = 100 No’s. Sessional Marks = 40 No's. Final Exams Marks = 60 No's.
- 4. Lecture No 1 07-01-2013 List of Text Books 1. Introduction to Modern Steel Making by R. H. Tupkary and V. R. Tupkary (2008) 2. The Making, Shaping and Treating of Steel (Steel Making and Refining) by Richard J. Fruehan, United States Steel Co., American Society for Metals ISBN-10: 0930767039, ISBN-13: 978-0930767037 3. Modeling of Steelmaking Processesby Dipak Mazumdar, James W. Evans ISBN-10: 1420062433 | ISBN-13: 978-1420062434 4. SecondarySteelmaking: Principles and Applications Ahindra Ghosh ISBN-10: 0849302641 | ISBN-13: 978-0849302640 5. Ironmaking and Steelmaking: Theory and Practice Ahindra Ghosh (Author), Amit Chatterjee 6. Physical Chemistry of Steel Making by John. F Elliott, ISBN-10: 0-262-55046-6, ISBN- 13: 978-0-262-55046-8 7. A Text Book Of Metallurgical Analysis Author: B C Agarwal P Jain and S C Sharma ISBN: 8174091351 Useful Link www.steeluniversity.org Make your own Notes it will be easy to understand any subject/topic
- 5. Lecture No 1 07-01-2013 MY-301: STEEL MAKING PROCESSES INTRODUCTION: Whatis steel? Differencebetween iron and steel making processes? Engineering practice of the reductionof Iron oxide 1) Reduction of Iron Oxide in Blast furnace by (Indirect Method): 2) Reduction of Iron Oxide in Shaft or Rotary Furnace by (Direct Method) or MIDREX® Process
- 6. Lecture No 1 07-01-2013 1)BLAST FURNACEby (indirect method) Iron is extracted from the ore haematite (Fe2O3) by reduction CO is a reducing agent because it is more reactive than iron Processor steps or (how iron is extractedfrom their ore)
- 7. Lecture No 1 07-01-2013 Hot air is blasted into the furnace causing coke (carbon)to burn rapidly and raise the temperatureto 2000 °C. (Exothermic reaction) C(s) + O2 (g) CO2 (g) + Heat The carbon dioxide then reacts with hot carbon to form carbon monoxide. CO2 (g) + C(s) 2CO (g) Carbon monoxide then reduces iron in the ore to iron metal. 3CO (g) + Fe2O3(s) 3CO2 (g) + 2Fe (l) The main impurity is silica (sand or rock) which is SiO2 SiO2 is solid at the furnace temperature and the furnace would become blocked if it was not removed Limestone is calcium carbonate(CaCO3) and it is added to the blast furnace to remove the impurities in the iron ore. Calcium carbonateis decomposed by heat in the furnace to give calcium oxide (lime) and carbon dioxide. This is called thermal decomposition. CaCO3(s) CaO(s) + CO2 (g) Silicon dioxide reacts with calcium oxide to form calcium silicate (called slag) which is liquid in the furnace. Slag flows to the bottomof the furnace where it floats on the liquid iron and is easily removed. CaO(s) + SiO2(s) CaSiO3 (l) The slag (CaSiO3) is allowed to cool until it becomes a solid and is used for road construction.
- 8. Lecture No 1 07-01-2013 2) Shaft or Rotary Furnaceby (Direct Method) or MIDREX®
- 9. Lecture No 1 07-01-2013
- 10. Lecture No 1 07-01-2013 Reduction: Iron oxide, in pellet or lump form, is introduced through a proportioning hopper at the top of the shaft furnace. As the ore descends through the furnace by gravity flow, it is heated and the oxygen is removed from the iron (reduced) by counter flowing gases which have a high H2 and CO content. These gases react with the Fe2O3 in the iron ore and convert it to metallic iron, leaving H2O and CO2. For production of cold DRI, the reduced iron is cooled and carburized by counter flowing cooling gases in the lower portion of the shaft furnace. The DRI can also be discharged hot and fed to a briquetting machine for production of HBI, or fed hot, as HDRI, directly to an EAF. Reaction in Reformer: CH4 + CO2 2CO + 2H2 CH4 + H2O CO + 3H2 Reaction in shaft Furnace: Fe3O4 + CO 3FeO + CO2 Fe3O4 + H2 3FeO + H2O FeO + CO Fe + CO2 FeO + H2 Fe + H2O