Code No: 45043

Code No: 45043 R07 Set No - 1
III B.Tech I Semester Regular Examinations,Nov/Dec 2009

IRON PRODUCTION
Metallurgy And Material Technology
Time: 3 hours Max Marks: 80
Answer any FIVE Questions
All Questions carry equal marks
?????
1. (a) Explain under what conditions of blast furnace burdening external desiliconi-
sation is accomplished.
(b) Describe how the high temperature required for the reduction of iron ore is
generated inside blast furnace. [10+6]
2. (a) Explain the applications of sponge iron.

(b) Briefly discuss about sponge iron production in India. [8+8]
3. Write short notes on the following:
(a) Hanging, types of hanging and its control.

(b) Slip formation, its effect and its control. [8+8]
4. (a) What are the raw materials used in Puddling process?

(b) Explain its advantages and disadvantages. [8+8]
5. (a) Explain the sintering principle. What are the various factors that influence
the quality of sinter? Explain them.
(b) Describe Sintering process in detail. [10+6]
6. (a) List out the various integrated steel plants in India & mention the sources of
raw materials and production capacity of each plant.
(b) What constitute the burden of a blast F/C? What are their functions? [8+8]
7. (a) What are the sources of sulphur in blast furnace iron production? Explain.
(b) Explain the chemistry of sulfur reactions in blast furnace. [8+8]
8. (a) With a neat sketch explain the working of ventury washer.

(b) What is electrostatic separator? What is its main application? With the help
of neat sketch explain the working of electrostatic separator. [8+8]
?????
1
IRON PRODUCTION
?????
1. Explain the causes for the formation of following, its effects and its control:
(a) Slip.
(b) Choking . [16]
2. Explain the three stages during the mechanism of ball formation during sintering
process.
(a) Nuclei formation.

(b) Transition region.
(c) Ball growth region. [16]
3. What is low shaft blast furnace? Discuss the raw materials used, advantages and
disadvantages of low shaft blast furnace. Explain with a neat sketch. [16]
4. What are the various factors on which the value of Iron ore depends? Explain all
of these factors in detail. [16]
5. What is skip hoist? Why is it used. Explain the working of skip hoist, giving the
details of the skip pit and top charging system. [16]
6. Explain the factors that control the sulphur reactions in the blast furnace hearth.
[16]
7. (a) Compare and contrast between wrought iron and pig iron.
(b) How wrought iron is made? Explain any one process of wrought iron produc-
tion. [8+8]
8. (a) What are the sources of silicon in the blast furnace burden? Explain them.
(b) Describe the various calcination reactions in blast furnace and how they help
to form gangue and slag. [10+6]
?????
2
IRON PRODUCTION
?????
1. Explain the causes for the formation of following, its effects and its control:
(a) Burning of tuyeres.
(b) Coke-mess. [8+8]
2. Explain in detail the various methods of green ball hardening. [16]
3. (a) Explain the differences in production principles of wrought iron making and
pig iron making.
(b) Explain the applications of wrought iron. [8+8]
4. (a) “For a given burden the alkali input cannot be controlled, only operational
controls can minimize the adverse effects”. Explain.
(b) Differentiate between primary slag, bosh slag and final slag in Blast furnace
iron production. [8+8]
5. What are the four different modes of cooling arrangement in blast furnace? Discuss
them.
[16]
6. (a) Explain about the older versions of blast furnance gas cleaning and charging
devices during iron production.
(b) Explain about pig casting machines. [10+6]
7. (a) Explain the effect of CaO, Al2 O3 &MgO contents of iron ore on the fluidity of
slags.
(b) What are the maximum temperature levels at the following regions during
blast furnace operation and explain the necessary reactions.
i. Tuyer level .
ii. Hearth level .
iii. Stack level. [8+8]
8. Write short notes on the following:
(a) Low shaft furnace.
(b) HYL process. [16]
?????
3
IRON PRODUCTION
?????
1. A blast furnace makes pig iron containing: C - 3.6%, Si - 1.4% and Fe - 95%. The
ore was 80% Fe2 O3 , 12% SiO2 , 8% Al2 O3 . The coke (1 kg per kilogram of pig iron)
carried 10% SiO2 and 90% C. The flux (0.40 kg per kilogram of pig iron) was pure
CaCO3 . The gas contained 28% CO and 12% CO2 . Required: Per ton of pig iron
made:
(a) The weight of ore used.
(b) The weight of slag made.
(c) The volume of the blast furnace gas. [16]
2. Write an essay on various methods/ techniques to improve the overall efficiency of
operation of blast furnace. [16]
3. (a) Explain the three stages of blast furnace gas cleaning.
(b) Explain the important uses of blast furnace gas. [12+4]
4. (a) What is wrought iron? How is it different from pig iron?
(b) What are the various methods of making wrought iron? Discuss any one
method. [8+8]
5. Explain briefly the following with respect to Blast furnace opration:
(a) Blowing-in.
(b) Blowing-out.
(c) Draughting. [16]
6. (a) What are the factors which results in low silicon iron in Blast furnace route?
Explain.
(b) Discuss the effect of alkali metals and their compounds in iron making. [8+8]
7. (a) What is pelletizing? What are pellets? Explain. What is the size range of
iron ore fines suitable for pelletizing. Discuss.
(b) Explain the working principle of briquetting. What are the advantages and
disadvantages & applications? [10+6]
8. (a) Discuss the iron ore deposits in India & world with an emphais on the type of
ore, iron content in the mineral , etc.
(b) Briefly explain about the details of iron ore exports from India. [12+4]
?????

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Code No: 45043 R07 Set No - 1

III B.Tech I Semester Regular Examinations,Nov/Dec 2009

2. (a) Explain the applications of sponge iron.

3. Write short notes on the following:

(a) Hanging, types of hanging and its control.

4. (a) What are the raw materials used in Puddling process?

8. (a) With a neat sketch explain the working of ventury washer.

(a) Nuclei formation.

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