Iron Making - Merged
Iron Making - Merged
Iron Making - Merged
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History
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Extraction of Metal
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Iron Ore to Steel
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Odisha, which accounts for over half
of India’s iron ore production,
produced 120 million tonnes during
the 2019/2020 year to March, up
slightly from 118 million tonnes the
previous year.
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State wise Hematite ore in india
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▪ Private steel companies like TATA Steel, Mittal
Steel, Essar, Jindal etc. also produce hot metal in
Blast Furnace route.
▪ More than 90% Iron is produced in India through
the blast furnace route.
▪ This is the most versatile and energy efficient
process, economical and higher productivity and
hence used for mass production all over the world.
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Conventional process BLAST
FURNACE.(Hot Metal)
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Nonconventional Processes
COREX :
A “coke less” iron making process, that also generates
electricity. Jindal Vijayanagram Steel Plant (JSW) uses
corex technology. (Non-Coking Coal)
FINEX :
Low operating cost process that uses iron ore fines and
non coking coal to produce liquid hot metal.
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FINMET : An optimized fine ore reduction process for the
direct utilization of low-cost iron ore fines to produce hot
briquetted iron (HBI).
MIDREX : Midrex is natural gas-based shaft furnace
process that converts iron oxides in the form of pellets or
lump ore into direct reduced iron (DRI).
ROMELT : It is a slag bath reduction process which uses
iron ore fines directly for hot metal production. One
commercial plant is being set-up in India.
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Top steel
producers
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Steel Plants in India
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Thank you
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Iron making
F.S.B.E.III (Metallurgical & Materials Engg.)
Content
• Iron Ore
• Limestone ----------→
• Coke
Iron Ore
• For a rich lump ore, crushing and sizing to between 6mm and
35mm, and blending to overcome variations in chemical
composition are the only pre-treatments needed before
feeding into a blast furnace.
• However, if Fine ore were to be used as feed to a blast
furnace its powdery nature would restrict the passage of the
blast air up through the furnace, limiting its permeability. The
problem of using the fines is overcome by agglomerating the
ore into sinter or pellets.
• Granular fines are more suited for sintering whereas very fine
material of close size range is better for pelletizing.
Coke
• Coke is formed by heating coal to 2100 F
(1150 C), then cooling it in quenching
towers.
• Metallurgical coke must be hard and
porous while still being physically strong.
• It used as a fuel and provides high heat
• It supply carbon for the reducing reactions
which convert iron oxide to metallic iron
• It provide a permeable support for the
feed materials charged into the furnace so
that the reducing gases derived from the
'air' blast can pass up the furnace to
provide the carbon which is dissolved in
pig iron.
Limestone
Volatile matter – 2%
P – 0.018% - 0.04 %
S- 0.6 % to 1.5%
Types of metallurgical coal
Metallurgical coal
F.S. BE III
IRON MAKING
• Burden preparation
• Burden qualities
CONTENT • Methods of beneficiation
• Agglomeration of iron ore
• Sintering process
TREATMENT OF IRON ORE
• Burden preparation
• Burden distribution is one of the key operating parameters influencing
blast furnace performance, particularly the productivity and the coke
rate.
• The proper distribution of burden materials improves bed permeability,
wind acceptance, and efficiency of gas utilization.
• In furnaces operating with high coal injection rates, the distribution
resulting in predominant central working (steep cohesive zone profile)
was found to be beneficial.
• The blast furnace is essentially a furnace working on the counter
current principle.
• The descending solid charge meets a current of ascending gases and
reduction of iron ore along with its progressive heating must take place
during this passage.
• The production rate of blast furnace is directly determined by two
important factors:
• The rate of reduction of iron oxide.
• The rate of heating of the burden.
BURDEN PREPARATION –I
(TREATMENT OF IRON ORES)
• The development in the field of iron making have always been
directed to increasing the productivity of B.F at minimum of fuel
consumption .
• Low Si and S contents obtain consistent and better quality of pig iron
owing to consequent economy in the steel making process.
• Effective process control and thereby maximum productivity can be
achieved
• If better quality charge materials, with respect to their uniform size.
• Adequate strength
• Good reducibility
IDEAL BURDEN QUALITIES
• Physical :
1. A close size range with minimum of fines
2. An ability to withstand the physical stresses incurred
on being transported to the furnace ,charged to the
hopper and bells, finally in the furnace.
3. Ability to with stand mildly reducing conditions at
lower temperature w/o breaking.
4. Low swelling during reduction.
▪ Chemical
1. High % of iron and low gangue contents.
IDEAL BURDEN 2. A low % of silica, alumina, etc and a low
QUALITIES alumina/silica ratio.
3. Proper overall chemistry to ensure clean
slag and metal separation
4. Free flow of both slag and metal from the
furnace opening.
BURDEN PREPARATION
• This method is used when the ore material is heavier than the
gangue material. The finely powdered ore is washed down through a
steam of water over vibrating sloped table with long wooden stripes
called riffles( forming grooves ).
• The heavier ore materials are obstructed by the riffles and settles
down the grooves and the lighter ones are washed always. These
ore materials deposited are collected from the grooves and used
for further processing of the gravity separation processes, the
spiral concentrators and circular jigs are two of the most
economical due to their simplicity and use of little space.
• They operate by flowing film separation and can either use wash
water or be wash water-less. The wash water spirals separate
particles more easily but can have issues with entrainment of
gangue with the concentrate produced.
GRAVITY METHOD
10000C
COHESIVE ZONE Isotherms
(LOWER STACK &
BOSH) 12000C
Isotherms
COKE SLIT
ACTIVE COKE ZONE
FUSED SLAG
(BOSH+HEARTH)
Tuyere Gas & Fe
RACEWAY-
DEAD MAN
2000OC
MECHANICAL COKE
SLAG&COKE
SUPPORT TO
BURDEN METAL&COKE
• Granular zone:
• Cohesive zone:
• Hearth zone:
Sintering process
Chapter 2
F.S. BE III
(Metallurgy & Materials Engg.)
ASSISTANT PROFESSOR
• Why preparation?
❑ To minimize the fluctuation in the quality of final product
• What is preparation?
❑ Raw material preparation for sinter making can be explained as crushing, mixing
& granulation of raw materials with different physico-chemical properties and
proportion of the same (iron ore fines, flux fines, fuel fines, metallurgical wastes)
to provide a homogeneous mixture, so as to produce sinter which has a good
and consistent metallurgical properties.
Raw Material Preparation
• Preparation of sinter mix exerts considerable influence on productivity,
quality (RDI,RI), consistency of sinter chemistry as well as machine
operation.
• Quality and productivity are determined by coke combustion behavior
during sintering process.
❑ Chemical composition
❖ Low in silica & low in alumina
❖ Lower alkali content
❖ Lower Sulphur
PARAMETERS OF DRUM
❑ Speed and inclination angle of drum is adjusted to achieve
residence time of 1 – 3 minutes
❑ Generally the drum length is three times higher than it’s diameter
IMPROVEMENT IN MIXING EFFICIENCY OF MIXER BY
❑ Increase in mixing time
❑ Optimisation of speed and angle of the drum
❑ Increase the length of the drum
High intensity mixer
• Advantages of using High
intensity mixer:
➢ Mixing and homogenization of sinter mix to the
level achieved in a base mix yard
➢ Ultra fines can be used in sinter mix
➢Increase the size of the ore fines to a level acceptable to the blast
furnace.
➢To form a strong agglomerate with high bulk reducibility.
➢To remove volatiles like CO2 from carbonates , H2O from hydroxide or
sulphur from sulphides type of ore fines along with their agglomeration.
➢To incorporate flux in the burden.
here adding flux in the sinter than separate addition in charge material
from top of b.f greatly improves the blast furnace performance.
Advantages
Prepared by :
Mr. Utkarsh V Prajapati (Assistant professor)
(Metallurgy & Materials Engg. Dept.)
BLAST FURNACE REACTIONS
• Reaction in Stack
• Reaction in Bosh
• Reaction in Tuyere
• Direct & Indirect reduction.
• Slag-metal reactions
• Desiliconisation
• Desulphurization
Reactions in different part
1. Tuyere zone – combustion zone
2. Stack - Including kinetics of iron oxide reduction
3. Bosh – fusion zone
4. Hearth – Desulphurization , Desiliconisation
Tuyere zone
• Cokeis the only constituents of the burden that descends down into the
Tuyere zone in the form of a solid column.
• Temperature at Tuyere level is around 1500⁰C .
• Sucha high preheated coke burns in front of Tuyere with great intensity and
turbulence when it comes in contact with 800-1300 ⁰ C , which generates
around 1900-2000 ⁰C.
• Thecombustion zone is in the form of a pear shape ,called raceway’ in which
the hot gases rotate at high speeds carrying a small amount of burning coke in
suspension.
• The situation in a blast furnace tuyere zone is practically ideally an
adiabatic system as define in classical thermodynamics.
• The burning of coke in front of the tuyere zone is almost instantaneous and
hence the theoretical adiabatic flame temperature in the raceway can be
calculated without any difficulty.
• This is known as RAFT in short.
• This
is the highest temperature available side of this zone. This is
temperature gradient in vertical direction on either side of this zone.
• This temperature is critically related to the hearth temperature .
• And this raceway is the vital part of
blast furnace.
• The structure of raceway largely
depends upon the quality of coke.
• Coke containing large amount of fines
tends to raise the pressure in the
raceway .
• Coke containing less fines exhibits
excellent permeability and form the
stable raceway.
• The volume and depth of raceway therefore deteriorates when quality of coke
deteriorates.
• Any lack of penetration of raceway might lead to decrease in temperature along
the vertical axis of the furnace - a situation detrimental to furnace operation.
• Hence main reactions are
• Although coke rate varies from furnace to furnace and it is as low as 450
kg/t of hot metal produced in some of the very efficient furnaces, it is
generally around 600-750 kg/t of metal product.
• Major portion of this coke burns at the tuyere level to provide major portion
of heat .
•A certain portion of the coke is consumed in the stack in solution loss
reaction .
• There is always some moisture in the blast ; it is more in rainy and less in summer.
{H2O} + <C> = {CO} + {H2}
• Which is generates additional reducing agent in the form of H2.
• Above reaction is endothermic in nature.
• If the extra heat is available at tuyere level then reaction will be useful.
• Unfortunately combustion also releases ‘S’ present in the coke, which is practically
all absorbed by the charge in the stack and is thus carried down into the hearth.
Reaction in stack
• The functions of the blast furnace stack are two fold.
1. It should progressively reduce the iron oxide to iron using CO of the gas
phase.
2. It should extract sensible heat from the ascending gases and thereby get
itself heated.
• The effluent gases at the stock line are usually at around 200⁰C and 1.3 atm
pressure with CO/CO2 ratio usually in the range of 1.5-3.0 .
• The equilibrium CO/CO2 ratio for
is small.
• Even if reaction as in eq.s
• Were to achieve equilibrium at the stock line the CO/CO2 ratio is not much.
• Below 800⁰C the CO content of the gases is more than the value in
equilibrium with the FeO or C.
• The presence of iron and iron oxide act as catalyst for the deposition
reaction which can be hazardous for the fireclay refractories in the upper
part of the furnace .
Lower part of stack
➢{SiS} = Si + S
• And partially bosh slag also absorbs ‘S’ as <CaS> (coke ash) = (CaS) in slag.
• The metal and slag beads trickling through the bosh zone have been
collected from working furnaces. Their analyses reveal that the Sulphur in
metal decreases and that in slag increases during their passage through the
bosh zone unto the slag surface in the health.
Reactions in Hearth
• Hearth is that part of the furnace where the molten products of the blast furnace
process accumulate and stay there until these are tapped out periodically.
• Herein bosh region itself because of prevailing high temperature melting takes
place. There are two immiscible liquid products of the blast furnace smelting
process.
• One is metallic phase - iron and all other elements
• One is oxidized phase – oxides like alumina , magnesia , alkali oxides , alkaline
earth oxides , silica ,Mno and S.
• These trickles down through the bosh and the tuyere and collected to hearth.
• The slag is tapped out every 2-3 hrs.
• Since
the molten metal trickles down through the coke bed in furnace it is
remains molten at 1200C.
• Slag consists of CaO,SiO2 ,Al2O3 constituting 90 % slag + oxides like MgO
,alkalies ,FeO.
• In order to obtain molten metal itis necessary that both the metal and slag form
thin free flowing liquids , so that these clarify into two clear liquid phases and
tapped separately .
• If no flux is added and if only silica and alumina are the main gangue
constituents of the ore the liquidus temp of this combination is too high.
• Flux like CaO is added to evolve a composition such that the liquidus is in
the range of 13-1400 c .
• Most of the deposites contains silica and alumina and therefore need a lime
as flux to obtain proper slag composition.
• Obviously the liquidus temperature of the slag is much higher than that of
the metal and therefore the operating temperature of a blast furnace is
always at least 50-100 C above the liquidus temperature of the slag formed.
• At this temperature both the slag and metal will be thin free flowing liquids.
• In reality the blast furnace operating temperature are in the range of 13-
1500 depending upon the total gangue in the burden and the flux is added.
Desulphurisation
• The slag composition has also to be viewed form that point of view of its
reactions with the metal, in particular its desulphurising ability..
• Since it is the main reactions that occurs in the hearth.
• The ‘S’ transfer across the slag – metal interface along with the associated
reactions are often described in below manner:
• [S] + [C] + (CaO) = (CaS) + CO2
• K= a (CaS). a (FeO)
a[FeS].a(CaO)
• K= %(CaS). (%FeO)
[%FeS]. (%CaO)
DESULPHURISATION INDEX
• (%s) directly proportional to (%Cao) / (%FeO)
[%s]
• The ratio (%s) / [%s] is referred as the desulphurising index and which varies with basicity
and the oxygen potential.
• The oxygen ion concentration in slag is
represented by (CaO) or similar basic oxides in
the slag and the oxygen potential of the system
is represented by either (%FeO) or [%O].
• The ratio (%S)/[%S] is often referred to as the
Desulphurising index and which varies with
basicity and the oxygen potential as shown in
figure
CONDITION FOR SULPHUL REMOVAL
• Temperature- high
• Basicity-high
• Atmosphere-reducing
Prepared by :
Mr. Utkarsh V Prajapati (Assistant professor)
(Metallurgy & Materials Engg. Dept.)
content
1. Constructional features of blast furnace,
2. Blast furnace profile,
3. Refractories,
4. Accessories,
5. Charging mechanism,
6. Bell and Belless charging systems.
What is refractory ?
FORMED
UN-FORMED
UN-FORMED
DRY
REFRACTORIES
Classification
Classifications
BLAST FURNACE REFRACTORY LINING