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. 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 blasting, to produce a finished casting. 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. The making of cast iron begins with a combination of raw materials. Apr 19, 2012 the steel making process in the oxygen converterconsists of. Sampling and temperature measurement tapping the steel to a ladle. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. A simplified flow diagram of sponge iron making in rotary kilns is given in fig51. Designing iron sponge process for h2s removal student. This intermediate product is subsequently melted in electric arc furnaces or induction furnaces. With the technology of bottom air pulsation added with modern process control features and improved product discharge mechanism, batac jig of humboltz wedag have been successfully installed. The latter process is based on atomization of a stream of liquid. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron.
Iron making process iron coal free 30day trial scribd. Recent development of ductile cast iron production. Steel making steel making process gerdau ameristeel utilizes the electric arc furnace continuous casting method in the production of structural steel products. Hi all, i am a final year student in australia and am trying to complete my design project. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. I have come to understand that this is a fixed bed adsorber column design but i cannot find much.
Casting process simulation of compacted graphite iron 03. Iron and steel production complete notes ebook free download pdf. Iron making process, full notes, pdf, ebooks, popular topic for study. Alternative ironmaking technologies costly and scarce coking coal.
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. Ironmaking and steelmaking metallurgical and materials. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. One of the major challenges for sponge iron plant is the accretion formation. New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. It constitutes 5 percent by weight of the earths crust, and it is the. Iron and steel production complete notes ebook free. The steel making process in the oxygen converterconsists of. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Pdf process monitoring of ironmaking process in a blast. Ferrous metallurgy is the metallurgy of iron and alloys.
Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. Metallurgical engineering industrial production of iron ore ebook download pdf metallurgical engineering. Recycled steel scrap provides the raw material for the electric arc furnaces eaf. Iron and steel have both played an important role in the development of human civilisation over several millennia and have found uses in agriculture, construction, the generation and distribution of power, the manufacturing of machinery and equipment, in the household and in medicine. Figure 73 shows a typical vessel for the iron sponge process.
The mixing, agglomeration, and feeding steps are the same as in the production of dri or bfs, but the rhf is operated. Designing iron sponge process for h2s removal posted in student. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder. Steel exchange india limited is having a sponge iron manufacturing unit in technical collaboration with world renowned ms mannesmann demag of germany codir process. The iron ore concentrate is now mixed and ready for the pelletizing process. It is a metal that belongs to the first transition series and group 8 of the periodic table. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic ironnickel. Sponge iron production by direct reduction of iron oxide. The pelletization process is the primary consumer of binders in the iron ore industry. Pig iron is divided into steel making 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. Study on accretion formation on dri kiln during spong iron production chandrashekhar shrivas, himanshu shrivas abstracttoday is an era of competition, and contrary to this the iron and steel industries are also suffering from the same. To eliminate fossil fuel use in iron and steel making, renewable hydrogen gas can be used in place of syngas to produce dri. Alternatively dri grade pellets which are produced from iron ore fines can also be purchased and utilized instead of iron ore. Processes that produce iron by reduction of iron ore in solid state below the.
The global steel industry is using about 28 to 30 percent of alternative iron like drihbi, merchant pig iron and hot metal to produce quality steels. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace. The present scenario of iron and steel sector is very much challenging. Beneficiation of indian high alumina iron ore fines a case study. Direct reduction processes can be divided roughly into two categories. Directly reduced iron directly reduced iron is a product of. Together with coal and cotton, iron and steel were the principal materials upon.
Iron manufacturing process related to the specified. 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. Green steelmaking with the midrex and fastmet processes. Commercial sponge iron powder production dates back to 1903 with the invention of the sieurin process in sweden. Study on accretion formation on dri kiln during spong iron. The sponge iron is delivered as hot from the reduction shaft furnace by screw.
The main raw materials used for the production of sponge iron is. The most common process is the use of a blast furnace to produce pig iron which is about 9294% iron and 35% carbon with smaller amounts of other elements. For a long period of time it was the major ironmaking technique, but the develop ment of coke was the twilight era for sponge iron, except in. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Several grades of treated wood chips are available, based on iron oxide content. This section basically explains the system function in detail. With an installed capacity of 2x350tpd and can able to produce sponge iron of 0.
Ironmaking and steelmaking are energy intensive and essentially all the carbon entering a steel complex leaves as co2. Extractive metallurgy, lecture notes, pdf, ebooks, attached files for direct download. Iron ore is converted into various types of iron through several processes. A thesis submitted for partial fulfillment of the degree. Step 1 the production of molten iron the primary concentrate is mixed with limestone and coal and heated. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Appropriate beneficiation process has to be advanced to reduce the waste generation in mines and for the sustainable growth of the iron ore industry some. The itmk3 process uses lowgrade iron ore 3 and coal other feedstocks can be used as supplements to produce iron nuggets whose quality is superior to that of dri 97 percent iron content but is similar to that of pig iron. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Slime in these tailing ponds contains iron values in the range of 4560%. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. How iron is made material, manufacture, making, history. In the corex process, a combination of lump ore, pellets, and sinter is prereduced to about 90% metallization sponge iron in the reduction shaft furnace by a gas containing co and h 2 supplied from the melter gasifier, which is the main reactor of the corex plant. The iron in use for centuries is found in the combination of iron and other elements.
Iron making process, full notes, pdf, ebooks, results 1 to 1 of 1. Slag, which floats on top of the iron, has the function of removing impurities from the iron and its chemical composition and temperature to a large extent determine the chemistry and hence quality of the iron. It is by mass the most common element on earth, forming much of earths outer and inner core. The reducing gas is a mixture majority of hydrogen h2 and carbon monoxide co which acts as reducing agent. Related manufactures description of manufacturing process m1. This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is directly reduced in the solidstate, using either natural gas or noncoking coal, to produce a highly metallised material, referred to as sponge iron or direct reduced iron.
Pig iron has only limited uses, and most of this iron goes on to a steel mill where it is converted into. Alternative emerging ironmaking technologies for energy. For years, iron and steel industry has been in search for low cost alternative to the conventional blast furnace production of iron as well as new routes for recycling of byproduct which are generated during production and treatment of iron and steel. The second principle is that discovered by hess 1840. The manufacturing process iron ore is converted to steel via two main steps. Feed material the iron ore fines sample was collected from the spiral classifier overflow of a typical iron ore beneficiation plant of noamundi, india. Any excess iron can then go back to be melted down again. Process features developed by moscow institute of steel and alloys misa in mid 1980s process operates under a slight negative pressure 15 mm wc greater raw material flexibility accepts iron ore, slimes and other iron bearing materials in a wide range of sizes 0 20 mm without any pretreatment. Introduction compacted graphite iron cgi has been known since the nineties as a highstrength casting material figure 1. Iron making process free download as powerpoint presentation. Coal is another main raw material for process of sponge iron and both indian coals and imported coals can be used for the process. 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. Beneficiation of indian high alumina iron ore fines a case.
The iron impurities oxidize, evolving heat, necessary forthe process. I have come to understand that this is a fixed bed adsorber column design but i cannot. 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 chips are contained in a vessel, and sour gas flows through the bed and reacts with the ferric oxide. The selection of an appropriate binder type and dosage is of critical importance in producing good quality pellets at a reasonable price. Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes, slagforming agents and solid fuel coke. Primus, a new process for the recycling of steelmaking by. The molten iron has a dissolved carbon content of approximately 3. After the iron has cooled in the moulds it is broken out. The first involves the production of molten iron and the second is that of actual steel manufacture. The casting process is an art that must be examined and experienced to be fully understood. Iron ore beneficiation current practices in india first iron ore jig was installed in barsua iron ore mine of sail. Fundamentals of iron and steelmaking 39 equal to its heat of formation, but of opposite sign. Our vibrating products are applied for various manufacturing processes of broad industries, and obtaining high reputations.
This product is known as direct reduced iron dri or sponge iron. Iron powders iron powder made by sponge iron process, atomization processes gas and water and electrolysis. The dri process has the ability to use low grade coal that is unacceptable for conventional iron making. I am tasked with designing the equipment for the iron sponge oxide process for the removal of hydrogen sulphide from natural gas. Directreduced iron dri, also called sponge iron, is produced from direct reduction of iron ore in the form of lumps, pellets or fines by a reducing gas produced from natural gas or coal. Need to look beyond coking coal possibility to use iron ore fines directly landconstraint environmental considerations eliminate pollutionintensive sintering and. It is the fourth most common element in the earths crust in its metallic state, iron is rare in the. Recent development of ductile cast iron production technology. 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. In all coalbased dr processes using rotary kilns, sized.