Steel Plant

Steel Plant
Process Overview
Karan Sagar, 03/06/2021

Steel Making Can be divided into 2 main Steps:
Iron Making Process Steel Making Process

Flow Chart of Iron Making Process
Coke Oven
Transfer of Hot Metal
Sintering/Pelletisation Blast Furnace Taphole Blast Furnace Trough

Plant
Torpedo Ladle
Hot Stoves
Hot Dirty Gases Slag

Coke Oven
(Iron Making Process)
• Coking or Carbonisation of Coal via

destructive distillation of Coal to increase
Calorific value by converting it into Coke
• Temp in Coke Oven - ~1100℃
• Heat transferred to Coal through conduction
from Silica refractories
• Silica refractories are used because of their
RUL & Creep and reliable volumetric
stability at high temperature. (Silica phase -
Tridymite)
• Time spent in oven - 22-25 hrs
Sintering Plant Pellet Plant
(Iron Making Process)
• Materials input - Iron ore fines, Coke • Iron ore fines are concentrated, and
Breeze and fluxes (dolomite and mixed with binders (Bentonite, clay,
limestone) hydrated lime, etc) and then balled to
• Iron ore fines are concentrated and form green bodies
sintered into bigger chunks for better • Temp - 1300 ± 50℃ in oxidising
Blast Furnace efficiency. condition
• Temp - 1300 ± 50℃ • Good porosity - 18%
• Refractory used - Andalusite and • Refractory used - Andalusite and
Mullite brick Mullite brick
Hot Stoves
Iron Making Process
• Cold Blast air is heated here by passing through

chequer bricks before blasting it into the Blast
Furnace
• Waste gaseous product from Blast Furnace and
Coke Oven can be utilised for heating the
chequer work
• Chequer bricks Refractory - Silica bricks ,
sometimes Alumina brick is used
• Hot blast temp- 1000℃
Blast Furnace
Iron Making Process
• Raw material - Iron ore/pellet/sinter,

limestone, Coke charged from Top.
• Hot blast air through tuyeres in the Bosh
area.
• Fe2O3 reduced to Fe by CO and C and drips
to Hearth as Liquid metal
• CaO reacts with SiO2 to form slag
• Hot Metal extracted through Taphole
• Refractory used in Hearth - Carbon brick
Refractory
uses in
different zones
Iron Making Process
of Blast
Furnace
Taphole
Hot Metal Transfer
• Helps in discharging Hot metal from Blast

Furnace to Torpedo Ladle through Trough
Runner
• Mud gun is normally used to drill out the
taphole and release the Hot Metal.
• Resin/Tar bonded plastic refractory based on
clay material containing different percentage
of C normally used in tap hole during
operation are normally called Taphole clay.
Blast Furnace
Trough Runner
Hot Metal Transfer
• It helps to transfer Hot
Metal coming out from
Blast Furnace Taphole
to Torpedo Ladle
• There is normally 3
sections in this zone:
Main Trough Runner,
Hot Metal Runner, Slag
Runner
• SiC based Trough
Castable normally used
in this section for better
performance
Torpedo Ladle
Transportation of Hot Metal
• Torpedo Ladle normally carries Hot Metal
from Blast Furnace section to SMS (Steel
Melting Shop)
• Refractory lining normally used is containing
ASC Brick as Working lining and Charge
Pad
• In Mouth section - High Alumina (Low
cement ) Castable
• It contains a Safety lining as a backup,
Insulating layer and has an Outer Steel Shell.
Flow Chart of Steel Making Process
Torpedo Ladle
DS Plant Primary Steel Making Secondary Steel Making Casting of Steel
Ladle Furnace
BOF/ LD Convertor
RH Degasser
CAS-OB
DS (Desulphurisation) Plant
• Removes Sulphur from hot metal then the

hot metal poured into BOF for Steel
making
• Reagents used - CaO, CaC2, Mg
• Injection Lance made of Refractory
material uses during operation and
process homogenisation
Types of Steel Making
Primary Steel Making Secondary Steel Making
• Conversion of Hot Metal to Steel • Changing the composition of Steel to

• Reduction of Carbon % from ~4.1% to match Clients’s requirements
0.4 to 0.7% • Can be done through various
• Done through BOF processes. Ex: RH degassing, CAS-
OB, Ladle furnace
• Alloy addition and other chemistry of •
liquid steel up-gradation normally

done in Secondary Steel making
LD Convertor / BOF
(Basic Oxygen
Furnace)
Primary Steel Making
• Hot Metal is converted to Steel
• C % reduced from 4.1% to 0.04-0.07%
• impurities (Mn, Si, P) removed via the use
of Oxygen.
• Top, bottom or mixed blowing of Oxygen
are used
• Charge handled per operation 310-330MT
• Refractory used - Mag-Carbon bricks in
the inner layer, Magnesite bricks for outer
layer
LD Convertor / BOF
(Basic Oxygen
Furnace)
Primary Steel Making
• The BOF steel making process gets completed in 40 mins.
Ladle Furnace
Secondary Steel Making
• Reheating of liquid steel by electric

power using graphite electrodes
• Continuous purging of Ar for
homogenisation of temp and chemistry
• Change in chemistry can be achieved
by addition of ferro-alloys, cored-wire,
dephosphorisation and deep-
desulphurisation
RH Degasser
Secondary Steel Making
• Used to remove H2 and N2 by passing

liquid steel through a vacuum chamber.
The decrease in pressure leads to
disintegration into the smallest parts.
This increase in surface area allows the
degassification.
• The addition of alloying elements during
degassing has the advantages of
achieving higher yields for ferro alloys
and high accuracy of chemical analysis
of steel due to the absence of air and the
avoidance of metal slag reactions.
• Decarburisation can also be performed.
CAS-OB (Composition
Adjustment by Sealed
Argon
Secondary
Making
bubbling
Steel with
Oxygen
•
Blowing )
Chemical heating of Steel using Al and
O2 lance along with alloy addition for
desired composition
• Ar bubbling for homogenisation from
Porous plug and additional lance
• Refractory- High Alumina Castables
reinforced with 2% stainless steel
needles.
Flow Chart of Casting Process
Casting of Steel
Slide Gate Plate Ladle Shroud Tundish Submerged Entry Continuous Casting
Nozzle
Direction of Process Progression

Casting of Steel
• After completion of Secondary Steel

making, to provide a permanent shape to
the liquid steel, casting process plays an
important role
• Normally Zirconia based black Refractory
is used in this zone - Slide Plate, Shroud,
Monoblock Stopper, Submerged Entry
Nozzle, etc.
• Mould containing Copper and spayed cold
water are used during the solidifying
process of liquid steel.
• Tundish plays imp role during Casting

Steel Plant

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Steel Plant

Karan Sagar, 03/06/2021

Iron Making Process Steel Making Process

Transfer of Hot Metal

Sintering/Pelletisation Blast Furnace Taphole Blast Furnace Trough

Hot Dirty Gases Slag

• Coking or Carbonisation of Coal via

• Cold Blast air is heated here by passing through

• Raw material - Iron ore/pellet/sinter,

• Helps in discharging Hot metal from Blast

DS Plant Primary Steel Making Secondary Steel Making Casting of Steel

• Removes Sulphur from hot metal then the

• Conversion of Hot Metal to Steel • Changing the composition of Steel to

liquid steel up-gradation normally

• Reheating of liquid steel by electric

• Used to remove H2 and N2 by passing

Direction of Process Progression

• After completion of Secondary Steel

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