Iron and Steel Production PDF

Iron and Steel Production
IRON AND STEEL PRODUCTION
Iron making - iron is reduced from its ores
MECN 4140 - Manufacturing Processes Inter American University of Puerto Rico Prof. Eduardo Cabrera Ruiz
Based on 2007 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 3/e
Steel making iron is then refined to obtain desired purity
and composition (alloying)
Page 2
Iron Ores Required in Iron-making

The principal ore used in the production of iron and steel is
Iron Ore
hematite (Fe2O3)
Other iron ores include magnetite (Fe3O4), siderite
(FeCO3), and limonite (Fe2O3-xH2O, where x is typically around 1.5) depending on grade (hematite is almost 70% iron)
Iron ores contain from 50% to around 70% iron, Scrap iron and steel are also widely used today as raw
Hematite
Magnetite
materials in iron- and steel making Limonite

Page 3 Page 4
Pellets
Other Raw Materials in Iron-making

Coke (C)
Other Raw Materials in Iron-making

Limestone (CaCO3)
Supplies heat for chemical reactions and produces carbon monoxide (CO) to reduce iron ore
Used as a flux to react with and remove impurities in molten iron as slag
Hot gases (CO, H2, CO2, H2O, N2, O2, and fuels)
Mineral Carbon
Page 5
Coke
Used to burn coke
Page 6
Iron-making in a Blast Furnace

Blast furnace - a refractory-lined chamber with a diameter of about 9 to 11 m (30 to 35 ft) at its widest and a height of 40 m (125 ft)
To produce iron, a charge of ore, coke, and limestone are
Blast Furnace
dropped into the top of a blast furnace

Hot gases are forced into the lower part of the chamber at
high rates to accomplish combustion and reduction of the iron
Page 7
Page 8
Chemical Reactions in Iron-Making

Using heated air (O2) with coke:
2C + O2 heat + 2CO
Using hematite as the starting ore:
Fe2O3 + CO 2FeO + CO2

CO2 reacts with coke to form more CO:
Figure 6.5 Cross-section of iron-making blast furnace showing major components
Page 9
CO2 + C (coke) 2CO

This accomplishes final reduction of FeO to iron:
FeO + CO Fe + CO2
Page 10
Proportions of Raw Materials In Iron-Making

Approximately seven tons of raw materials are required to
Iron from the Blast Furnace

Iron tapped from the blast furnace (called pig iron)
produce one ton of iron: 2.0 tons of iron ore 1.0 ton of coke 0.5 ton of limestone 3.5 tons of gases
A significant proportion of the byproducts are recycled
contains over 4% C, plus other impurities: 0.3-1.3% Si, 0.5-2.0% Mn, 0.1-1.0% P, and 0.02-0.08% S
Further refinement is required for cast iron and steel
A furnace called a cupola is commonly used for converting pig iron into gray cast iron For steel, compositions must be more closely controlled and impurities brought to much lower levels
Page 11
Page 12
Steel-making
Since the mid-1800s, a number of processes have been
Basic Oxygen Furnace (BOF)

Accounts for 70% of steel production in U.S Adaptation of the Bessemer converter
developed for refining pig iron into steel

Today, the two most important processes are
Bessemer process used air blown up through the molten pig iron to burn off impurities BOF uses pure oxygen
Typical BOF vessel is 5 m (16 ft) inside diameter and can
Basic oxygen furnace (BOF) Electric furnace

Both are used to produce carbon and alloy steels
process 150 to 200 tons per heat Cycle time (tap-to-tap time) takes 45 min
Page 13
Page 14
Basic Oxygen Furnace
Figure 6.7 Basic oxygen furnace showing BOF vessel during processing of a heat.
Page 15
Figure 6.8 BOF sequence : (1) charging of scrap and (2) pig iron, (3) blowing, (4) tapping the molten steel, (5) pouring off the slag.
Page 16
Electric Arc Furnace

Accounts for 30% of steel production in U.S. Scrap iron and scrap steel are primary raw materials Capacities commonly range between 25 and 100 tons per
heat
Complete melting requires about 2 hr; tap-to-tap time is 4
hr
Usually associated with production of alloy steels, tool
steels, and stainless steels

Noted for better quality steel but higher cost per ton,
compared to BOF
Page 17
Page 18
Casting Processes in Steel-making

Steels produced by BOF or electric furnace are solidified for
subsequent processing either as cast ingots or by continuous casting Casting of ingots a discrete production process Continuous casting a semi-continuous process
Figure 6.9 Electric arc furnace for steelmaking.

Page 19 Page 20
Casting of Ingots
Steel ingots = discrete castings weighing from less than one ton up to 300 tons (entire heat)
Molds made of high carbon iron, tapered at top or bottom
Ingot Mold
for removal of solid casting

The mold is placed on a platform called a stool
After solidification the mold is lifted, leaving the casting on the stool
Page 21
Figure 6.10 A big-end-down ingot mold typical of type used in steelmaking.

Page 22
Continuous Casting
Continuous casting is widely applied in aluminum and
copper production, but its most noteworthy application is steel-making

Dramatic productivity increases over ingot casting,
which is a discrete process

For ingot casting, 10-12 hr may be required for casting to
solidify Continuous casting reduces solidification time by an order of magnitude

Page 23
Figure 6.11 Continuous casting. Steel is poured into tundish and flows into a water-cooled continuous mold; it solidifies as it travels down in mold. Slab thickness is exaggerated for clarity.
Page 24
Steel
An alloy of iron containing from 0.02% and 2.11% carbon by weight
Often includes other alloying elements: nickel, manganese, chromium, and molybdenum Steel alloys can be grouped into four categories: 1. Plain carbon steels 2. Low alloy steels 3. Stainless steels 4. Tool steels End Lecture 3 Lecture 4
Page 25
Page 26
Virtual Field Trip Huachipato in Chile
Materia Prima
Page 27
Page 28
Separacin por Densidad
Trituracin
Page 29
Page 30
Separacin por Magnetismo
Sinterizacin
Page 31
Page 32
End Lecture 3 Lecture 4
Page 34

Iron and Steel Production PDF

Uploaded by

Copyright:

Available Formats

Iron and Steel Production PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Iron and Steel Production PDF

Uploaded by

Copyright:

Available Formats

Iron and Steel Production

IRON AND STEEL PRODUCTION

Iron making - iron is reduced from its ores

Steel making iron is then refined to obtain desired purity

and composition (alloying)

Iron Ores Required in Iron-making

materials in iron- and steel making Limonite

Other Raw Materials in Iron-making

Other Raw Materials in Iron-making

Used to burn coke

Iron-making in a Blast Furnace

dropped into the top of a blast furnace

high rates to accomplish combustion and reduction of the iron

Chemical Reactions in Iron-Making

Fe2O3 + CO 2FeO + CO2

CO2 + C (coke) 2CO

Proportions of Raw Materials In Iron-Making

Iron from the Blast Furnace

Basic Oxygen Furnace (BOF)

developed for refining pig iron into steel

Basic oxygen furnace (BOF) Electric furnace

Basic Oxygen Furnace

Electric Arc Furnace

steels, and stainless steels

Casting Processes in Steel-making

Figure 6.9 Electric arc furnace for steelmaking.

for removal of solid casting

Figure 6.10 A big-end-down ingot mold typical of type used in steelmaking.

copper production, but its most noteworthy application is steel-making

which is a discrete process

solidify Continuous casting reduces solidification time by an order of magnitude

Virtual Field Trip Huachipato in Chile

Separacin por Densidad

Separacin por Magnetismo

End Lecture 3 Lecture 4

You might also like