INGLESE

BLAST FURNACE STEEL

Intoduction

Ilva is a steel plant that uses two different technological processes for its production of raw steel: the integral
cycle and the electrometallurgical cycle.

The former is the most widely used. It consist of a set of operations and machines that permit to obtain
metallurgical products starting form raw materials in their natural state.

Chemical reaction and process

The fossil carbons and the iron minerals are taken from their deposites.

The fossil carbons are blended and distilled in the cockery (made up of a series of fornace) to produce
metallurgical coke. It plays an important role about the chimical reduction in the manufacturing processo f
liquid iron in a blast furnace.

The iron mineral is processed in the preparation plant which, through crushing, riddling and blending of the
different types of minerals available, enables a material to be obtained that has the chimical composition
suitable for loading into the blast furnace.

In the blast furnace coke reacts through combustion with oxygen of the air blows in the furnace at high
temperature (1200 °C). The principal product of this reaction is carbon dioxide.

It reacts with other carbon of coke forming carbon monoxide.

Carbon monoxide is the reducing agent.

In fact progressively going down into the blast furnace varoius chemical reactions take place in the layers of
burst furnace.

In general several types of iron oxide are formed and react with carbon monoxide.

Finally pure iron is obtained and with an other reaction, two composites are formed: cast iron and carbon
bioxide.

The latter is volatile and lighter than other materials, so it moves up favouring reactions.

If the blocks of iron are compact, the reduction is completed by carbono of coke. This is called direct
reduction.
The liquid cast iron is moved by special railway trucks called torpedo wagons beacuse of their particular
shape.

Another possible operation consists of LD process that permits to refine the material depriving it of part of
carbon. In this way we obtain steel (so in general the final material is an alloy of carbon and iron but on the
basis of the percentage of the elements of carbon and iron, we define it steel or cast iron).

LD process consist in blowing oxygen through launching.

Final product

In the converter a specific quantity of scrap iron is added to achieve thermal balancing of the process.

The liquid steel is poured into a ladle with iron alloys necessary to reach the desired chimical composition.

The solidification of the steel takes place by casting in continuous casting machines in which ingot moulds
are included with a section equal to taht of the product to be manifactured.

The solidified semi-product is cut to the destre lenght through the use of oxygen-lance shears and is
transferred by roller sto the evacuation cooling bed.

The semi-finished products are then heated in special fornace and rolled in rolling mills, for transformation
into finished products.
PRODUCTS OF LAVORATION

/ TINPLATE AND CHROME PLATE COILS AND SHEETS

Tinplate is the most commonly used material for making steel-based containers for the food industry and
other sectors.

It consists of a thin sheet of mild steel known as basic steel, electrolytically coated with a thin layer of tin
and protected against atmospheric oxidation by passivation treatment and a film of natural oil.

/ HOT-DIP ZINC AND ALUMINIUM COATED COILS

The coils, normally cold rolled and pickled, are sent to the hot-dip coating lines where they are first annealed
and then, after thorough surface preparation, coated.

Coating is obtained by continuous hot- dip in zinc or aluminium-silicon alloy and guarantees lasting
protection, making the product suitable for a vast range of applications.

Thanks to these characteristics, together with the high drawability and formability typical of cold rolled steel,
hot-dip coated coils lend themselves for use in the automotive sector, industrial and civil metalwork, the
building industry and structural applications in general.

/ ELECTRO-GALVANIZED COILS

Electro-galvanized products have a zinc coating applied electrochemically to both or only one of the
surfaces.

The electro galvanizing process makes it possible to obtain a zinc coating of high chemical purity and
perfectly controlled thickness both longitudinally and transversely.
FORGING

Abstract

The basic concept discussed here is using about forging process by different equipments like machines,
pneumatic hammer, forging, furnaces, saddles, dies etc.

The use of forging is to reduce material wastage and manufacturing time, avoids complex machining
operations and used for mass production.

Forging includes various operations like up-setting, punching, roll forging and flattening. The process
includes heat treatment and proof machining also.

Pneumatic forging hammers, hand tools like saddles, mandrels, punches, calipers and tongs will play
prominent role in this process.

Introduction

Forging is the process by which metal is heated and is shaped by plastic deformation by suitably applying
compressive force. Usually the compressive force is in the form of hammer blows using a power hammer or
a press.

Forging refines the grain structure and improves the physical properties of the metal. With proper design, the
grain flow can be oriented in the direction of principal stresses encountered in actual use. Grain flow is the
direction of the pattern that the crystals take during plastic deformation.

Physical properties (such as strength, ductility and toughness) are much better in a forging than in the base
metal, which has, crystals randomly oriented.

A Forged metal can result in the following :

• Increase length, decrease cross-section, called drawing out the metal.

• Decrease length, increase cross-section, called upsetting

the metal.

• Change length, change cross-section, by squeezing in closed impression dies. This results in
favorable grain flow for strong parts