Iron production process pdf

Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. The high temperatures are needed for the reduction of iron and the oxidation of the. It constitutes 5 percent by weight of the earths crust, and it is the. Iron ore lump ore, pellets, or a mixture thereof is charged into the reduction shaft, where it is reduced to direct reduced iron dri by the reduction gas in counterflow. Steel production engineering materals ii meng 2122 12. The iron ore pelletizing process consists of three main steps. Some experimental work performed by the writer in 1911 under a carnegie research scholarship of the iron and steel institute of great britain, and the work of others, serve to show the metallurgical possibilities of the electric furnace for the production of pig steel from ore, and whether the process satisfies the five stated requirements. In iron ore, iron is presents in its oxidised form. Integrated iron and steel manufacturing production of steel from iron or e or iron ore pellets.

A typical blast furnace may be up to 32 metres in height and 10 metres in diameter. Cast iron production when breaking out the casting the sand mould is destroyed, but of course new moulds can be made from the pattern using the same sand after it has been recycled. Steel production american iron and steel institute. This section deals with the types of iron and steel which are produced as a result of the steelmaking process. Cast iron that has not cooled evenly produces a lowquality cast. Blast furnaces are used continuously and are only shut down when their brick lining needs replacing. As a result of these impurities, iron must be first separated from the gangue and then converted to pure iron.

According to the world steel association, world crude steel production has increased from 851 million tonnes mt in 2001 to 1,606 mt in 20 and world average steel use per capita has steadily increased from 150kg in 2001 to 225 kg in 20. The first stage is to produce pig iron from iron ore in a blast furnace. However, scrap steel, both quantitatively and qualitatively, cannot meet the entire demand for steel. 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 blast furnace uses coke, iron ore and limestone to produce pig iron. The modern steel production process methods for manufacturing steel have evolved significantly since industrial production began in the late 19th century. Stidies on process kinetics intensification of dri making and improvement in prouct. During this treatment, graphite changes from flakes to nodules or spheres. Bhavesh r rana and others published ironsteel making. Pdf ironsteel making from start to finish researchgate. Reference is also made to techniques which will be relevant to the proposed integrated pollution and prevention ippc regulations.

The production of iron from its ore involves an oxidationreduction reaction carried out in a blast furnace. Limestone, in small quantities, is also required to scavenge the sulphur. Discharge screws convey the dri into the melter gasifier, where final reduction and melting take. The production of wrought iron or steel is a process containing two main stages.

The first step of the production of ductile iron cast. Gph tmt 500w bar is produced by fully automatic, computerized machines based on sophisticated and accurate advanced technology and design. In the subsequent oxidation step, the iron ore is reoxidised by water vapour yielding an hydrogen rich fuel gas. The casting process is an art that must be examined and experienced to be fully understood. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. Production processes and reaction evolution analysis article pdf available in chemical engineering communications 2037 november 2015 with 2,745 reads how we measure reads. 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 second raw material, cast iron borings, is a byproduct from the machining of cast iron parts.

Steel manufacturing and finishing processes discussed in that document are also employed in integrated. The second is to make wrought iron or steel from pig iron by puddling process a further process. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Direct reduction processes can be divided roughly into two categories. The process of mining low grade iron ore, or taconite, requires massive resources. Commercially available iron is classified based on. The overall process synthesizes ammonia from molecular nitrogen and hydrogen by feeding the reactants over iron catalysts at a high pressure and temperature, requiring bulky, wellinsulated reactors to house the process.

It supersedes her majestys inspectorate of pollutions chief inspectors guidance notes ipr 21 and ipr 23 published by hmso in 1994. The raw materials used include ore, sinter, coke, lime and various aggregates. The treatment process is a key operation in the production of ductile iron that ensures a predetermined microstructure, and mechanical and engineering properties of castings. Process gases, for example, from the coke oven, bf or bof are also important coproducts. The primary processes covered by this note are sinter production, pelletising, blast furnace iron making, desulphurisation, basic oxygen and electric arc steel. Hydrogen production by steamiron process sciencedirect. Modern methods, however, are still based on the same premise as the original bessemer process, which uses oxygen to lower the carbon content in iron. Although the dominant use of iron is in metallurgy, iron compounds are also pervasive in industry. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. The major raw materials required for production of sponge iron by the rotary kiln process are. Production process and energy saving technology ironmaking process steelmaking process rolling process. It plays a significant role in reducing waste and provides an efficient raw material for iron making. Coke making not colocated with an integrated iron and steel manufacturing process. Modern methods, however, are still based on the same premise as the original bessemer process, which.

Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. To ensure that the production process maintains a high and stable level of quality, these materials have to be metered precisely and supplied to the blast furnace in batches. The first blast furnaces appeared in the 14th century and produced one ton per day. Salzgitter the process shown above is illustrative. In both cases, the objective of the process is to drive off the oxygen contained in various forms of iron ore sized ore, concentrates, pellets, mill scale, furnace dust, etc.

This is accomplished by the method of pyrometallurgy, a high temperature process. Melting steel scrap results in liquid steel, which can be shaped in the desired forms by casting, rolling and finishing. Iron ore is usually a mixture of iron and vast quantities of impurities such as sand and clay referred to. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work was conducted in it. Therefore, further stabilizing ductile iron production process, improving ductile iron quality, exploiting and introducing new. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. They are then used to help heat the air blast, required if blast furnace is to reach the high temperatures needed to produce molten iron. The thoroughly tested billets are reheated under controlled temperature in automatic reheating furnace at 11001200c and are subsequently rolled through a sequence. Iron catalysts are traditionally used in the haberbosch process for the production of ammonia and the fischertropsch process for conversion of carbon monoxide to hydrocarbons for fuels and lubricants. Recent development of ductile cast iron production technology. Wrought iron is quite soft and easily worked and has little structural strength.

The sintering process converts finesized raw materials, including iron ore, coke breeze, limestone, mill scale, and flue dust, into an agglomerated product, sinter. Overview of the steel and iron ore arket overview of the global iron and steel maret production trends according to preliminary data from the world steel association wsa, global production rose 4. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. An infographic of the iron and steel manufacturing process by tracey sinhaspinks 06. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. Ductile iron is made by the treatment of molten iron with nodulizing spheroidizing material. Chapter 6 copper production technology the last boomin technological innovation for the copper industry occurred in the first two decades of this century, whenopen pit mining, flo tation concentration,and the reverberatory smelter were adapted to porphyry copper ores. Products slabs rounds by products engineering materals ii meng 2122. The figure shows a flowchart of the integrated manufacturing process for iron and steel using the blast furnace and basic oxygen furnace denoted bf and bof hereinafter, respectively, which is presently the most commonly used method 51% of world steel production. Feb 11, 2016 iron rod manufacturing process at balanagar near mahabubnagar dist. The first known european breakthrough in the production of cast iron, which led quickly to the first practical steel, did not come until 1740.

Sintering is an important part of the overall process. This is the final part of the process and the one most people associate with foundries. How iron is made material, manufacture, making, history. Recent development of ductile cast iron production. Production of pig iron in a blast furnace 6 even though there is evidence of iron production in crucibles already in ancient times, reduction of lump ores by charcoal was used for its practical use at the beginning of iron industry. It is a cyclic process for water cleavage, whereby coal is consumed. Entire nations launched efforts to discover the process. Other problems faced during the cast iron process include contamination of the iron, gas porosity the forming of bubbles in the iron, and problems with the fluidity of the metal. Jun 21, 2016 in this method, iron ore is mixed with coke and heated highly in order to form an ironrich clinker called sinter. In the subsequent oxidation step, the iron ore is re. The bos process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal and scrap is used for temperature control. The main coproducts produced during iron and crude steel production are slags 90% by mass, dusts and sludges. The iron and steel production source category consists of facilities with any of the following processes.

The iron ore concentrate is now mixed and ready for the pelletizing process. Processing techniques and productions of ductile iron. Production of ductile iron is influenced by a large number of metallurgical, technological, heat transfer and designing parameters. Iron ore is usually a mixture of iron and vast quantities of impurities such as sand and clay referred to as gangue. Even though equipment is improved and higher production rates can be achieved, the processes inside the blast furnace remain the same. If all the carbon is removed from the iron to give high purity iron, it is known as wrought iron. Creating steel from lowgrade iron ore requires a long process of mining, crushing, separating, concentrating, mixing, pelletizing, and shipping. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process.

Ironmaking and steelmaking metallurgical and materials. Introduction to iron and steel a few definitions and general descriptions are in order iron. One raw material in the laux process is nitrobenzene, obtained by the nitration of benzene with nitric acid. The iron found in iron ores are found in the form of iron oxides. Iron with a bit of carbon in it generally less than 1%. They have thick steel sides, lined with refractory bricks, to ensure that heat is not lost. In essence, all primary iron and steel production processes are based on the same chemical reactions.

The latter process is based on atomization of a stream of liquid. Jan 14, 2020 the modern steel production process methods for manufacturing steel have evolved significantly since industrial production began in the late 19th century. Steel production is a 24houraday, 365dayayear process, dependent on a consistent supply of raw materials and huge amounts of energy. The steamiron process is one of the oldest methods of producing hydrogen. A simplified diagram of a blast furnace is drawn below. Apr 27, 2015 4272015 11 production of pig iron process scrap change vessel converter converter operation furnace pig iron ladle metallurgy 3. Coal is gassified to a lean reducing gas, containing carbon monoxide and hydrogen. This rapid increase in crude steel production has also resulted in significant increases, as shown in fig. The following describes operations at the national steel pellet company, an iron ore mining and processing facility located on the mesabi iron range of minnesota. The european iron workers knew the easterners had better iron, but not the processes involved in fashioning stronger iron products. The first involves the production of molten iron and the second is that of. The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform fe metallic of all grain size fraction of the product.