IRON MAKING

STEEL MAKING

CONTINUOUS
CASTING

ROLLING
Production of Iron occur sometime after 2000
BCE in south-west or south-central Asia maybe
The Iron replaced
Bronze in weapons and
implements.
Alloyed with a bit of
carbon dioxide
Harder, more durable
and sharper edge
Basis of human
civilization in Europe,
Asia and Africa
 It is the fourth most abundant element that makes up 5% of earth’s crust
 It is found naturally in iron ore also known as iron stone
 It is an oxide of Iron.
 Contains varying quantities of other element such as Silicon, Sulfur,
Manganese and Phosphorus
rocks from which metallic iron can be
economically extracted. These rocks are
usually found in the form of hematite
(Fe2O3) or magnetite (Fe3O4). About 98%
of world iron ore production is used to
make iron in the form of steel.
 1.Coke-oven-
Sinter-BF
route
IRON MAKING 2.Direct
Reduction
PROCESS Technique
3.Smelting
Reduction
Technologies
COKE-OVEN-
SINTER-BF-
ROUTE
 SCHEMATIC
DESIGN OF COKE
OVEN BATTERY
The technology involves charging about 30% coal blend in the form of
briquettes.
Briquettes are prepared using a binder (pitch/ pitch+tar) upto 2. to 3.0% of
charge.
Coke quality significantly improves as a result of increase in bulk density of
charge.
The technology basically involves formation of a stable coal cake with finely
crushed coal (88-90% - 3mm) by mechanically stamping outside the oven
and pushing the cake thus formed inside the oven for carbonisation.
Coal moisture is maintained at 8-10% for the formation of cake. Due to
stamping, bulk density of charge increases by 30-35% causing significant
improvement in micum indices and CSR values of coke.
Oven productivity increases by 10-12% & there is a possibility of using
inferior coking coals to the extent of about 20%.
In this technology, the aim is to improve homogeneity of reactive & inert
components in coal by reducing the difference properties of coarse & fine
size fractions.
Here the red-hot coke is cooled by inert gases, instead of conventional
water quenching.
It not only effectively utilises the thermal energy of red-hot coke (80% of
the sensible heat of coke can be recovered & made use of for production of
steam) but also results in improvement of the coke quality (M10 index can
be improved by 1 point).
 is the
technology for

SINTERING
agglomeration
of iron ore fines

PROCESS into useful ‘Blast

Furnace’
burden
material.
• Use of iron ore fines, coke
breeze, metallurgical
wastes, lime, dolomite for
hot metal production
• Better reducibility and
other high temperature
properties
• Increased BF productivity
• Improved quality of hot
metal
• Reduction in coke rate in
blast furnaces
The hot metal output from the Blast
furnace is either directly fed in to the
Basic Oxygen Furnace or used for
producing ‘pig iron’.
This technique produces 97.0 percent
pure iron, which is called,solid
Sponge Iron
Smelting Reduction Technologies

In this process, the hot metal (liquid iron) is produced from iron ore in two
steps. Ores are partly reduced in the first step and then final reduction
andmelting, takes place in the second stage.
Corex Technique

Here coal is directly used in a melter gesifier as an energy carrier &

reducing agent, thereby eliminating the need fora Blast Furnace, Sinter Plant
& Coke Ovens
Other techniques used:
-Hismelt
-Ausmelt-
Romelt
-Plasmasmelt
-Iron Smelting Reduction (DIOS)
Iron is replaced by steel in 1870 CE
Types of techniques:
1.Basic Oxygen Furnace (BOF) type
2.Electric arc furnace (EAF) type.
 is a pear shaped vessel lined
inside with refractory bricks . The
vessel lining consists of tar bonded
dolomite /magnesia carbon bricks
or other refractories. The vessel
can be rotated 360 o on its axis .
Oxygen is blown into the vessel

BASIC
with the help of water cooled
lance.
The 'heat' begins with the addition
of scrap into the slightly tilted
convertor, hot metal is then added

OXYGEN
after straightening the convertor,
Oxygen is blown into the bath
through the lance .The necessary
fluxes are added during blowing
.Flux addition is done
automatically and precisely

FURNACE
through bunkers situated above
the converters.
A sample is taken after blowing for
16-18 minutes and temperature is
measured using a thermocouple.
The steel is tapped by tilting the
convertor to the tapping side and
alloying elements are added via
chutes while metal is being tapped
The convertor is tilted to the
charging side in order to remove
the floating slag .
Electric arc
furnace
(EAF) type.
Molten steel cast in vertical cast iron moulds
intended for rolling after heating in two stages
liquid steel is directly cast into semi-finished products, which eliminates the
need for primary rolling of ingots.
The crude steel or liquid steel is poured into a reciprocating refractory-
lined receptacle, called a
Tundish.
tundish is a broad, open container with one or more holes in the bottom. It
is used to feed molten metal into an ingot mould so as to avoid splashing
and give a smoother flow.
Below the Tundish are water-cooled copper moulds of desired size.

The steel solidified in the moulds is slowly pulled out to produce an

"endless" strand,which is gas-cut to desired lengths.

This steel is called semi-finished steel. The semi-finished steel is fed in to

re-rolling mills to get finished steel products.