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Steel Making and the next steps
By
G. Venkateswara Rao
Sr. Manager (MP)
Bailadila Iron Ore Mine,
Kirandul complex
NMDC Limited
What is steel ?
---Alloy of Iron, Carbon, manganese, Chromium,
Vanadium, Nickel , tungsten and other elements
Importance of Steel:
High
Hardness
Ductility
Malleability
Toughness
Tensile strength
Cast ability
Low cost
Good Corrosion resistance
Reasons for wide range of
applications of steel
Ø Wide range of Alloy
Compositions
ØGood Mechanical Properties
ØVariety of Product forms available
ØPossibility of changing
Mechanical
Properties (Heat treatment)
Ø Small or large,
Ø High-tech or low-tech,
Steel Applications
Home Domestic appliances such as fridges,
washing machines, ovens and
microwaves, sinks, radiators, cutlery, hi-fi
equipment, razors, pins.
Power and Oil and gas wells and platforms, pipelines, electricity
energy power turbine components, electricity pylons, wind
turbines.
Electrical and Electromagnets, transformer cores, electromagnetic
Magnetic shields.
Yellow goods Earth-moving and quarrying equipment, cranes, fork-
lift trucks.
Agriculture and Farm vehicles and machinery, storage tanks, tools,
Industry structures, walkways, protective equipment.
* Up to 2009 December
Top 10 Steel Producing Companies (2008)
POSCO 34 . 70 4 th 33 . 90 4 th
Hebei Steel 33 . 30 5 th 32 . 20 5 th
JFE 33 . 00 6 th 32 . 80 6 th
Wuhan Steel 27 . 70 7 th 28 . 90 7 th
Group
Tata Steel 24 . 40 8 th 25 . 10 8 th
Group
Jiangsu 23 . 30 9 th 24 . 30 9 th
Shagang Group
US Steel 23 . 20 10 th 21 . 80 10 th
Categories/ Types of Steel Products
Steel Production - Consumption
01.) Coal from the mixing and grinding plant 09.) Quenching car
02.) Coal bunker 10.) Coke wharf
03.) Weighing containers 11.) Coke for the blast furnace
04.) Charging car 12.) Dedusting of coke output
05.) Coke oven chamber 13.) Coke pusher
06.) Riser 14.) Gas for the coal by products plant
07.) Regenerator 15.) Chimney
08.) Transfer machine
Cross section of Coke oven Battery
Coke ovens and by Product Handling Plant
Why Coking coal?
vTo remove volatile constituents like Water, Coal
Rate of Suction
Ø Applied Suction
q To increase porosity
Process flow of Pelletisation
Process of Pelletisation
v Feed Preparation
v Green ball production and sizing (5-20mm)
v Green ball Induration
--- Drying (400-500C)
--- Pre-heating (850-950C)
--- Firing (1250 – 1350C)
v Cooling of Hardened Pellets
Charge composition of Pellet Mix
Fuel
Constituent
Iron
Lime
Bentonite
Coke
Moisture
Consumption
Ore 12LPT
Percentage
90%Min
2-3%
0.5-1.0%
1-2%
5-10%
Concentrate
Rate of Production of Green balls Depend on
§ Diameter of Disc/Drum
§ Angle of Inclination
§ Speed of Rotation
§ Nature and size of Feed
§ Rate of Feed
§ Rate of moisture addition
§ Rate of Withdrawal of Product
Disc Pelletiser
Top View and Side View of Disc Pelletizer
Characteristics of Pellets
Physical Properties
SizeCompression
Bulk
Tumbler
Abrasion
Cold
Porosity
Green
Dry
Drop Density
Crushing
Index
IndexStrength
Number
Compressive
strength 9-16mm
Below
94.00%
5.00%Max
250Kg/P
20.00%
Strength 4Kg/P
6-7
1Kg/P
2.00 5mm
T/mMin
3Min 5%
85%Max
Min
Characteristics of Pellets
Metallurgical Properties
Low temperature
Reducibility
Swelling
Metallisation
Strength Index
after 60.00%Min
15%
92%
50Kg/P
+6.3mm
-0.50mm
Max
Min 90.00% Min
5.0Max
reduction test
breakdown
Travelling Grate Pelletizing Furnace
Raw Materials
for
Blast furnace
Iron Making
Raw Materials for Iron Making
v Size 10-80mm
Characteristics of BF Coke
q Size --- 25 - 80mm
q Fixed Carbon --- 80 - 85%
q Ash --- 10 – 15 %
q Volatile Matter --- 2% Max
q Alkalies --- 0.50Max
q Sulphur --- 0.70Max
q Phosphorous --- 0.30 Max
qAbrasion Index --- M10 ---10% Max
M40 --- 75-80 Min
qStrength after reaction- CSR – 55-60
qReactivity --- CRI below 25
q
q
Characteristics of Pellets
Physical Properties
SizeCompression
Bulk
Tumbler
Abrasion
Cold
Porosity
Green
Dry
Drop Density
Crushing
Index
IndexStrength
Number
Compressive
strength 9-16mm
Below
94.00%
5.00%Max
250Kg/P
20.00%
Strength 4Kg/P
6-7
1Kg/P
2.00 5mm
T/mMin
3Min 5%
85%Max
Min
Characteristics of Pellets
Metallurgical Properties
Low temperature
Reducibility
Swelling
Metallisation
Strength Index
after 60.00%Min
15%
92%
50Kg/P
+6.3mm
-0.50mm
Max
Min 90.00% Min
5.0Max
reduction test
breakdown
Characteristics of Lime Stone
BF Grade
High Temperatures
Modern Blast Furnace Plant and
Process
vBlast Furnace Proper
vHot Blast Supply Equipment
vGas Cleaning System and Gas Storage
Dust Catcher
Scrubber
Electrostatic Precipitator
vRaw material Storage and Handling
vLiquid Products Disposal
vProcess Control Equipments
Process flow of BF Iron Making
Outer view of Blast furnace
BF – Refractory lining
Refractories used in BF
Temperature profile of BF
Cross sectional View of Modern BF
Cross sectional View of Modern BF
Different zones of BF
Based on Shape
Direct Reduction
Indirect Reduction
Smelting Reduction
FeO + CO = Fe + CO2
CO2 + C = 2CO
Total FeO + C = Fe + CO
Indirect reduction
Hematite : Fe2 O3 + CO = 2Fe3O4 +CO2
at 500oC
at 600 to 900 o C
at 1100 to 1150 o C
Zones – Reactions
Removal of Gangue/ Impurities
Percentage 0.06
Fe
C
Si
Mn
P
S Hot Metal
94.00Min
0.70-1.50
0.30-
0.20 -0.40
-0.12
-0.70
0.13 0.01
Steel–0.03
99.40Min
0.30
0.01-
0.05 0.60
0.10
0.03
Si + O2 =
Reactions in the LD Converter
SiO 2
S + O2 = SO 2
C + O2 = Co 2
2C + O2 =
CO
4P + 5O 2 =
2P O
Main control parameters
(C,T)
q Good management of charging,
tapping and of the equipment.
Slag/Metal Reactions
Slag/metal reactions concern:
Si removal
This reaction is very fast and the total amount of silicon
is transferred to the slag in the first one third of the
blow
P and S removal
These reactions require a very accurate control of slag
formation and of the final slag composition in order to
guarantee the low contents sought for the liquid steel.
Of the two, dephosphorization is the most crucial and is analyzed here. To be
successful and cost efficient, the steelmaker has to consider both
thermodynamic and kinetic aspects.
Slag Treatment
ØBOF slag is generated at a rate of 60 to 100 kg per
tonne
of steel. After steel tapping, it is poured in a slag pot by
tilting the converter and dumped in the slag yard from
which it can be reclaimed.
ØCurrently, about half of this quantity gets
recycled internally, either in the sinter plant or
else used directly in the blast furnace. The
valuable elements thus recovered are Fe and
CaO.
Such in-plant slag recycling has been declining
Property Value
Specific Gravity > 3.2 - 3.6
Unit Weight, kg/m3 1600 - 1920
(lb/ft3) (100 - 120)
Absorption up to 3%
Typical steel slag chemical composition.
CaO
SiO
FeO
MnO
MgO
Al
P
S
Metallic
2O
2O
25 3 Fe
Constituent 40
1510
0.5
< -0.1
-310
8-40
52
19
1
10
Composition (%)
(70 - 80% FeO, 20 - 30%
Fe2O3)
Secondary steel Making
Continuous casting
Blooms/Slabs
Billets
Hot rolling
Cold Rolling
Forging
Casting
Heat treatment
Finished/Semi finished goods
Principle of Continuous Casting
Continuous Casting
Principle of Continuous Casting
Photograph of Continuous casting in VSP
Photograph of Continuous casting
Photograph of Continuous casting
Photograph of Continuous casting
Photograph of slab casting
Photograph of Slab casting
Photograph of Slab casting
Rolling Mills
Rolling
Room temperature
Above recrystalisation and in some special
temperature (1100C) cases up to 300C
Process of Hot rolling
Process of Hot rolling
Various rolling configurations
WELCOME
TAN Q