We regard itmk3 as the 3rd generation ironmaking process, whereas the current mainstream process of blastfurnaceconverter is the 1st generation and the direct reduction process such as midrex is the 2nd generation. Hello metallurgical engineering students, i am sharing the iron making pdf class lecture notes, ebook, book as per the metallurgical engineering course syllabus. The iron ore concentrate is now mixed and ready for the pelletizing process. Sintering is an important part of the overall process as it reduces waste and provides an efficient raw material for iron making. Ferrous metallurgy is the metallurgy of iron and its alloys. It constitutes 5 percent by weight of the earths crust, and it is the. This authoritative account covers the entire spectrum from iron ore to finished steel. It also presents new and improved solutions to producing high quality products with low greenhouse emissions.
Iron making process iron coal free 30day trial scribd. List of topics covered in iron making quick revision pdf hand written class notes, book, ebook for metallurgical engineering. Replica of the part to be cast and is used to prepare the mould cavity. T, burla person involved name designation and email. The text is recommended for metallurgists and engineers who would like to know more about the processes in iron and steel manufacture, the principles behind. It guides the reader through the production process from start to finish.
Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. After the iron has cooled in the moulds it is broken out. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. Pdf this book presents the fundamentals of iron and steel making. Iron making quick revision pdf notes, book, ebook for. Basic concept or summary s16 u a direct reduced iron dri production plant is a shaft reduction furnace to produce dri with large metal iron content by directly reducing iron ore or iron ore pellets with reducing gases. Corresponding to each temperature interval, typical reactions will take place. Various hybrid oxygen steelmaking processes, advanced trends in steel making, automation towards. The refining of iron to make steel is where the carbon content of hot metal is lowered, usually to less than 1 % by an oxidation process in a steelmaking furnace.
First, iron ore is mixed with coke and heated to form an ironrich clinker called sinter. Ironmaking and steelmaking metallurgical and materials. Pig iron is divided into steelmaking pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron ores from at least greece to india, and more.
It is the physical model of the casting used to make the mould. Making mould cavity material is first liquefied by properly heating it in a suitable furnace. In addition, it examines legislative regulations regarding greenhouse emissions all around the. A blast furnace charge consists of ore, fluxes and fuel. R h tupkary this book comprehensively deals with all of the key topics of iron making including blast furnace plants, operations and processes, raw materials, preparation, chemical processes, and more. The iron impurities oxidize, evolving heat, necessary forthe process. These iron making quick revision notes will help you prepare on the exam day and score good marks. It begins by tracing the history of iron and steel production, right from the earlier days to todays world of oxygen steelmaking, electric steelmaking, secondary. The mould is made by packing some readily formed aggregate. A falling stream of iron ore particles is directly converted to metal in just seconds using low cost natural gas. Inserting producttechnical information, companyir information, recruitment information. The making of cast iron begins with a combination of raw materials. The ironmaking process in the blast furnace is a heat and mass transfer process, and the furnace can be divided into different zones according to physical and chemical state of the feed and temperature. This book presents the fundamentals of iron and steel making, including the physical chemistry, thermodynamics and key concepts, while also discussing associated problems and solutions.
Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Additionally, steel company engineers, process technologists, and management will find this book useful with its fundamental. The open hearth process gradually replaced the bessemer process as the primary method for steel production. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. The physicochemical fundamental concepts of chemical equilibrium, activitycomposition relationships.
Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Beginning with a brief introduction to the ferrous alloys and metals, types and production of cast iron, production of compacted graphite irons, ductile iron, malleable cast iron and current status of steel making. The steel making process in the oxygen converterconsists of. In the area of steelmaking, bof plant practice including pretreatment of hot metal, metallurgical features of oxygen steelmaking processes, and their control form part of the book.
This book describes improvements in the iron and steel making process in the past few decades. All though the text of this book, wherever possible, controversy has been avoided by giving the popular modern iron making comprehensively deals with the vast and complicated subject in a language and style that is easy to. The book also discusses other topics such as secondary steelmaking. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. A novel flash ironmaking process department of energy. Geologists recognise various types of iron ore, classified chiefly according to iron fe content see table 1 below. Production of pig iron in a blast furnace 9 scheme of a blast furnace content.
Packaging technology as the cornerstone, we aim to develop a richer and more environmentally friendly lifestyle. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. This book focuses on agglomeration, or the size enlargement process, of iron ores. The majority of coke produced in the united states comes from wetcharge, by. Iron making process free download as powerpoint presentation. Theory and practice ebook written by ahindra ghosh, amit chatterjee. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. A brief description of each coking process is presented here. Analysis, control, and optimization uses a fundamental. Metallurgical engineering industrial production of iron ore ebook download pdf metallurgical engineering.
Liquid is poured into a prepared mould cavity allowed to solidify. The iron is then melted in the furnace and poured off to go into the awaiting moulds. Pdf basic concepts of iron and steel making researchgate. Steelmaking is the second step in producing steel from iron ore. In fact it is believed that iron makes up about 5% by weight of the earths crust.
The purpose of this book is to serve as a textbook, not only for college work. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Theory and practice by ahindra ghosh and amit chatterjee is a complete reference text material on metallurgy, the process of making iron and steel, primarily intended for undergraduate and postgraduate students of engineering. The iron in use for centuries is found in the combination of iron and other elements. All the excess iron from the process, the runners etc are cleaned off in a process known as fettling, which also includes grinding and shot. Once begun an ironmaking campaign might last thirty or forty weeks, nonstop. Ironmaking process an overview sciencedirect topics. Molten iron is produced directly using iron ore fines and noncoking coal rather than traditional blast furnace methods through sintering and reduction with coke. Finex is the name for an iron making technology developed by former siemens vai now primetals technologies and posco.
Even one twentyfoothigh furnace required enormous amounts of fuel, ore, and labor 265 bushels of charcoal and three tons of ore were required to produce one ton of iron. This project seeks to demonstrate the scaleup feasibility of the process allowing for new ironmaking capacity at a significantly lower capital cost than with traditional systems. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom hotrolled and coldrolled strip coils structural shapes. This process sits at the interface of mineral processing and extractive metallurgy. Obviously fuel and ore had to be constantly on hand, and gangs of men. It is widely distributed, combined with oxygen as iron oxides. The book is full of illustrative examples full of diagrams, charts and figures to make complex concepts easy to understand. To develop computational and mathematical abilities to be applied for process design and control. Magnetic separation is used to remove some of the undesirable minerals or gangue in the crushed ore. Slag or foundry waste is put to one side for disposal. Ironmaking 101 from ore to iron with blast furnaces.
Sampling and temperature measurement tapping the steel to a ladle. Iron making mm15020 5th sem b tech department of metallurgy and materials engineering v. With the development of sintering technology, a sintering plant has become a tremendous success for providing a phenomenal increase in. Itmk3r process the itmk3 separates nugget iron and slag directly from the iron ore fines and pulverized coal.
The process duration varies with the injection rate, hot metal chemistry, and desired final sulfur content, and is in the range of 5 to 30 minutes. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic ironnickel. Bhagat introduction the process of sinter making originated from a need to make use of fines generated in mines and in ore beneficiation plants.
It begins by tracing the history of iron and steel production, right from the earlier days to todays world of oxygen steelmaking, electric steelmaking, secondary steelmaking and continuous casting. It is the first step in making most of the products. Elimination of preliminary processing is claimed to make the plant for finex less expensive to build than a blast. Introducing technical information, cans, can forming methods, tulc manufacturing process. The book begins with a discussion of raw materials preparation and the beneficiation process. Metallurgical engineering iron production ebook free download pdf metallurgical engineering industrial production of iron ore ebook download pdf metallurgical engineering. Download for offline reading, highlight, bookmark or take notes while you read iron making and steelmaking. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process.
Casting is one of the oldest manufacturing process. Iron very rarely occurs in the earths surface as a metal. The entire history of steel from hunks of iron streaking through the sky, to the construction of skyscrapers and megastructures, this is the history of the worlds greatest alloy. Carbothermic reduction of iron ore hametite in blast furnace is a well known process. Modern developments in blast furnaces, including modelling and process control are discussed along with an introduction to the alternative methods of ironmaking. Pet bottlecanplasticmetal packaging container manufacturing.
Control and analysis in iron and steelmaking sciencedirect. Direct reduced iron dri production plant nippon steel engineering co. Iron ores with lower iron content such as taconite are first processed to concentrate the iron level and drive off volatile impurities. This would remain so probably at least for the first quarter of the century despite speedy depletion of coking coal reserves enhanced adoption of alternate routes for iron making for ultimate conversion to steel.
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