The figure shows a flowchart of the integrated manufacturing process for iron and steel using the blast furnace and basic oxygen furnace denoted bf and bof hereinafter, respectively, which is presently the most commonly used method 51% of world steel production. Sponge iron production flow chart raw material feeding to. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at temperatures below the melting. Guidance manual for iron and steel manufacturing pretreatment. With such dimension of notion we in our sponge iron manufacturing process through 4 kilns 1 350t and 3 500t laid up the best dri making process in india. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. Sponge iron and smelting reduction mtd 30metallurgical. The loss of iron in the slag should not be excessive. After the iron has cooled in the moulds it is broken out. The process duration varies with the injection rate, hot metal chemistry, and desired final sulfur content, and is in the range of 5 to 30 minutes.
The first involves the production of molten iron and the second is that of actual steel manufacture. Apr 27, 2015 4272015 11 production of pig iron process scrap change vessel converter converter operation furnace pig iron ladle metallurgy 3. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. The casting process is an art that must be examined and experienced to be fully understood. Iron manufacturing process related to the specified. Introduction compacted graphite iron cgi has been known since the nineties as a highstrength casting material figure 1. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. The conventional hydroelectric power stations are usually located overground at the foot of a dam or a hill slope on the banks of a river. The second is to make wrought iron or steel from pig iron by puddling process a further process. Iron ore is converted into various types of iron through several processes.
Primus, a new process for the recycling of steelmaking by. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. In the year 1908 use of tunnel kiln started for iron oxide reduction. All these plant will be based on haematite ore as raw material. Direct reduction refers to solidstate processes which reduce iron oxides to metallic iron at. Production of sponge iron powder by reduction of rolling mill.
The major raw materials required for production of sponge iron by the rotary kiln process are. Iron making process, full notes, pdf, ebooks, results 1 to 1 of 1. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Steel exchange india limited is having a sponge iron manufacturing unit in technical collaboration with world renowned ms mannesmann demag of germany codir process. All the excess iron from the process, the runners etc are cleaned off in a process known as fettling, which also includes grinding and shot blasting, to produce a finished casting. Any excess iron can then go back to be melted down again. Recent development of ductile cast iron production. Is 12263 pdf, 1987, method for determination of regidity of sponge irondri during. Research object, aim and methodology the research object of the present paper is a system of iron casts manufacturing in expendable moulds on automated foundry lines. The iron content is normally around 70 %, with traces of nonferrous metals and alkaline compounds. Originally referred to as marsredwas followed by yellow shades in 1920s. Iron manufacturing process related to the specified manufactures december 20 update. This product is known as direct reduced iron dri or sponge iron.
The most common process is the use of a blast furnace to produce pig iron which is about 9294% iron and 35% carbon with smaller amounts of other elements. Optimization of operating parameters for sponge iron production. For years, iron and steel industry has been in search for low cost alternative to the conventional blast furnace production of iron as well as new routes for recycling of byproduct which are generated during production and treatment of iron and steel. Therefore, further stabilizing ductile iron production process, improving ductile iron quality, exploiting and introducing new technologies for ductile iron production, are still an important task for chinese casting manufacturing industry. Don abernathy huntsman pigments and additives structural. Coal based sponge iron is a metallic product produced through direct reduction of iron ore in the solid state. To develop computational and mathematical abilities to be applied for process design and control. Direct reduced iron dri is a quality metallic product, produced from iron are, pellets etc. Pig iron is divided into steelmaking pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. By the process it should be possible to produce pig steel at a greater profit than by existing methods. Mill scale contains both iron in elemental form and three types of iron oxides. Related manufactures description of manufacturing process m1. The kroll process, a unique existing industrial process of sponge titanium 1, matured to an extent that substantial improvement in performance had become impossible, which was costly and energy.
Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. In 1954, more kilns came in operation in sweden and usa. It also contains traces of nonferrous metals, alkaline compounds and oils from the rolling process. Iron powders iron powder made by sponge iron process, atomization processes gas and water and electrolysis. The production of wrought iron or steel is a process containing two main stages. Pig iron has only limited uses, and most of this iron goes on to a steel mill where it is converted into. By modifying the manufacturing process of red and yellow, brown evolved. Based on this analysis, it is clear in india that the installation of beneficiation facilities exclusively for low grade hematitic iron. It constitutes 5 percent by weight of the earths crust, and it is the. Commercially available iron is classified based on.
The production of ductile iron using local sponge iron proved to be and sulfur content, is. This ar ticle is a firsthand description of the production and utilization of sponge iron from a new process, the hyl process, in mexico. Sponge iron making is a process in which iron ore lumps typically 5mm18mm size are tumbled with a select grade of iron coking coal little dolomite inside an inclined rotary kiln and control combusted in the presence of air for about 12 hours before the products are air cooled, magnetically separated, screened and size wise in finished. Considering the possibility of the use of the electric furnace to satisfy these requirements. Commercially available iron is classified based on purity and the abundance of additives.
Step 1 the production of molten iron the primary concentrate is mixed with limestone and coal and heated. Iron production produces the greatest cost to the environment and therefore has the largest tax of any phase of the products life cycle. Recent development of ductile cast iron production technology. Since 1911 the hoganas corporation has continuously manufactured sponge iron, although the early use for this product was as a feedstock for steel making. This section basically explains the system function in detail. Iron ore the quality requirement of sized ore for sponge iron production can be classified into. The iron ore concentrate is now mixed and ready for the pelletizing process. Iron and steel manufacturing pretreatment standards prepared by the industrial technology division office of water regulations and standards and permits division office of water enforcement and permits september 1985 u. Extractive metallurgy, lecture notes, pdf, ebooks, attached files for direct download. Production of sponge iron powder by reduction of a by. Ironmaking and steelmaking metallurgical and materials. The overall investment of underground machine hall is less than those of the superstructure of a surface power house of similar dimensions.
The making of cast iron begins with a combination of raw materials. Overview of foundry processes and technologies manufacturing metal castings definition metal casting enables the production of simple to complex parts that meet a variety of needs. The research was limited to analysing activities in the area of melting shop and smeltery functioning fig. Coal based spongeiron is a metallic product produced through direct reduction of iron ore in the solid state. In the research work we find that it is the incomplete reaction of coal that causes the major energy inefficiency in the process. A study is made of the reduction of mill scale to sponge iron using coke at different temperatures and times. Energy audit methodology of sponge iron manufacturing.
How iron is made material, manufacture, making, history. Chapter 6 copper production technology the last boomin technological innovation for the copper industry occurred in the first two decades of this century, whenopen pit mining, flo tation concentration,and the reverberatory smelter were adapted to porphyry copper ores. Rolling mill scale, reduction, sponge iron power, coke introduction mill scale is a steelmaking byproduct from the rolling mill in the steel hot rolling pr ocess. The furnace used must be adapted to continuous operation and the production of a large tonnage. Mill scale is a steelmaking byproduct from the rolling mill in the steel hot rolling process. Dri direct reduced iron or sponge iron as it is also called. The main raw materials used for the production of sponge iron is. Iron making process, full notes, pdf, ebooks, popular topic for study. The mean particle size of iron ore shall be restricted to 11mm in order to achieve uniform fe metallic of all grain size fraction of the product. Synthetic red iron oxide pigments were first produced in a laboratory setting in the 14th century. Products slabs rounds by products engineering materals ii meng 2122.
Pdf balance, thermodynamic and mainly kinetic approaches using methods of process engineering enable to determine conditions under which iron. Steel production engineering materals ii meng 2122 12. This result makes sense as the iron manufacturing process utilizes other sectors of the economy that have high environmental impacts. Because of the variety of products and processes in this industry, operations vary from plant to plant. Production of sponge iron powder by reduction of rolling. Sponge iron production flow chart raw material feeding to kiln iron ore, coal, dolamite rotary kiln conversion of raw iron ore into sponge iron cooler sponge iron cooling below 100deg by external water cooling intermediate bin desired quality for blending screening in product house lumps magnetic separation. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron ore in the form of lumps, pellets, or fines to iron by a reducing gas or elemental carbon produced from natural gas or coal. Quality management in the manufacturing process of iron.
Quality management in the manufacturing process of iron casts. Other problems faced during the cast iron process include contamination of the iron, gas porosity the forming of bubbles in the iron, and problems with the fluidity of the metal. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. The process consists of pouring molten metal into a mold containing a cavity of the desired shape. Study on accretion formation on dri kiln during spong iron.
Prefeasibility report iron ore beneficiation plant index chapters particulars page no. Direct reduced iron dri, also called sponge iron, is produced from the direct reduction of iron. Various manufacturing methods include, but are not limited to. Casting process simulation of compacted graphite iron 03025. For this purpose a case study of typical sponge iron production process is considered. Wrought iron process the blacksmith heats the iron in the forge and sculpts it with hammer and anvil into threedimensional form. Selvakumar, in reference module in materials science and materials engineering, 2017. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Casting process simulation of compacted graphite iron 03. Steam, air, or mechanical hammers are customarily used in the procedure, but the hand hammer always concludes the job.
The bos process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal and scrap is used for temperature control. Wrought iron process,how is wrought iron made,process of. High quality ductile iron castings of suitable mechanical properties. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. Metallurgical engineering industrial production of iron ore ebook download pdf metallurgical engineering. Production of sponge iron powder by reduction of rolling mill core. The electric arc furnace uses primarily electrical energy to supply heat to melt scrap steel, sponge iron, or mixtures of scrap and other iron units. Processes that produce iron by reduction of iron ore in solid state below the. Commercial sponge iron powder production dates back to 1903 with the invention of the sieurin process in sweden. The history of sponge iron production says that the need for development and commercialization of sponge iron manufacturing process arose in late 50s when electric arc furnaces eafs engaged in manufacturing steel started facing problems of availability of scrap of desired quality, the traditional source of their iron metallics.
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