Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Iron and steel manufacturing industry pollution prevention. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. However, scrap steel, both quantitatively and qualitatively, cannot meet the entire demand for steel. From the standpoint of the new millennium there must be realized a change.
The bos process uses pure oxygen, injected by a lance, for refining the relatively impure hot metal and scrap is used for temperature control. Steel is primarily produced using one of two methods. How stainless steel is made material, manufacture, used. Steel obtained from this process is called blister steel due to the blisterlike marks formed on the surface due to. Bhavesh r rana and others published ironsteel making. Since the 1960s, electric furnaces and basic oxygen. Modern methods, however, are still based on the same premise as the original bessemer process, which uses oxygen to lower the carbon content in iron. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon most important impurity are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel.
Coke making not colocated with an integrated iron and steel manufacturing process. Overview of the iron and steel manufacturing sector the iron and steel sector is an essential part of the u. The bearing is one of the machine parts that supports the highreliability of the system. It has a wide range of properties that are largely determined by its chemical composition carbon and other alloying elements. Hotdip galvanizing is the process of immersing iron or steel in a bath of molten zinc to produce a corrosion resistant, multilayered coating of zinc iron alloy and zinc metal. Doushanov encyclopedia of life support systems eolss prevent, reduce, or eliminate adverse environmental consequences in the iron and steel industry. In the conventional integrated steel manufacturing process, the iron from the blast furnace is converted to steel in a basic oxygen furnace bof.
The bessemer process was the first inexpensive industrial process for the massproduction of steel from molten pig iron. Aist has collaborated with purdue university northwests center for innovation through visualization and simulation to create a unique, interactive experience of the steel manufacturing process. The modern steel manufacturing process the balance. If all the carbon is removed from the iron to give high purity iron, it is known as wrought iron. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Steel production american iron and steel institute. An act worthy of being highlighted within the scope of steelmaking is the startup. Melting steel scrap results in liquid steel, which can be shaped in the desired forms by casting, rolling and finishing. Co 2 abatement in the iron and steel industry 5 steel is basically an alloy consisting of iron, 0. Iron and steel manufacturing effluent guidelines us epa. The primary processes covered by this note are sinter production, pelletising, blast furnace iron making, desulphurisation, basic oxygen and electric arc steel. Steelmaking is the process of producing steel from iron ore and or scrap. Pdf ironsteel making from start to finish researchgate. Ussr 21% of global steel production, japan 16%, usa 14%, germany 6%, china 5%, italy 4%, france and poland 3%, canada and brazil 2%.
Oct 28, 2014 process involved in manufacturing carbonization of coke blast furnace basic oxygen steel making bos electric arc method 3. The production of steel in an eaf is a batch process. This section deals with the types of iron and steel which are produced as a result of the steelmaking process. Jun 21, 2016 modern steel making process uses a blast furnace for manufacturing steel. Cycles, or heats, range from about 112 to 5 hours to produce carbon steel and from 5 to 10 hours or more to produce alloy steel. Steel is manufactured by the chemical reduction of iron ore, using an integrated steel manufacturing process or a direct reduction process. Check out this infographic for an overview of the products that make each stage of the iron and steel manufacturing process possible, from incoming raw materials to the final coating line. In the primary steelmaking step, liquid iron is converted into steel by the basic oxygen furnace bof process, or by melting scrap steel or direct reduced iron dri in an electric arc furnace. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. The regulation covers any facility that is engaged in iron or steel manufacturing.
The iron and steel production source category consists of facilities with any of the following processes. The conditions slowly diffuse carbon into iron and cause the carbon to become dissolved in the iron, raising the carbon percentage. Iron and steel sector naics 3311 and 3312 energy and ghg. Integrated iron and steel manufacturing production of steel from iron or e or iron ore pellets. Process involved in manufacturing carbonization of coke blast furnace basic oxygen steel making bos electric arc method 3. 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. 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. Jul 09, 2018 the recycled heat kept the metal liquefied for longer than the bessemer process, giving workers more time to add the precise amounts of carbonbearing iron alloys that turned the material to steel. Directly reduced iron directly reduced iron is a product of. Be able to understand basic layout of blast furnace, steelmaking shop and continuous casting process. Because of the variety of products and processes in this industry, operations vary from plant to plant.
To develop computational and mathematical abilities to be applied for process design and control. While the steel is immersed in the zinc, a metallurgical reaction occurs between the iron in the steel and the molten zinc. Since last century, volume of steel production of a nation was taken as an index of industrial development. Creating steel from lowgrade iron ore requires a long process of mining, crushing. Iii control of pollution in the iron and steel industry d. Basicoxygen furnace 4272015 engineering materals ii meng 2122 25 25. 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. The main byproducts produced during iron and crude steel production are slags 90%, dusts and sludges. In 1980 716 mln tonnes of steel was produced and the following countries were among the leaders.
Steelmaking is the process of producing steel from iron ore andor scrap. The latter process is based on atomization of a stream of liquid. The molten iron is mixed with recycled steel scrap and further processed in a basic oxygen furnace to make steel. This product is known as direct reduced iron dri or sponge iron. Among all the manufacturing industries, iron and steel industry holds an enviable position. Stainless steel can also be cut using flame cutting, which involves a flamefired torch using oxygen and propane in conjunction with iron powder. After the bfbof process, molten steel is controlled to a target composition. The other major steelmaking method involves the melting and refining of steel scrap in an electric arc. A short video clip illustrating the process of iron and steel making that can be viewed online by students or downloaded for showing in class. The molten iron is subjected to pre treatment and is converted to steel in a convertor or a basic oxygen furnace.
Carbonization of coke well graded coal is selected heated or carbonized to coke heated coal is cooled and proper coke are fed into the blast furnace for the farther process. Primary steel making includes converting liquid iron from a blast furnace and steel scrap into steel via basic oxygen steel making or melting scrap steel andor direct reduced iron dri in an electric arc. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron. A simplistic overview of the steelmaking process from iron ore to car body manufacturing is followed by an introduction to the south african steel industry and the technologies that it utilizes. Steel manufacturing equipment is typical of enormous line systems that operate continuously, 24 hours a day. Oxygen is blown into the bof which contains the molten iron from the blast furnace. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work.
The blast furnace is the first step in producing steel from iron oxides. Pig iron is divided into steel making 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. Guidance manual for iron and steel manufacturing pretreatment. The process starts in the center of the wheel with the three main ingredients of iron in the form of iron ore, coke and lime, which are fed into a blast furnace to produce molten iron. Hotdip galvanizing is the process of immersing iron or steel in a bath of molten zinc to produce a corrosion resistant, multilayered coating of zinciron alloy and zinc metal. Iron ore occurs as lump ore and fine ore, and the latter is often processed into sinter or pellets. The bessemer process wirral model engineering society. Iron ore processing for the blast furnace courtesy of the national steel pellet company the following describes operations at the national steel pellet company, an iron ore mining and processing facility located on the mesabi iron range of minnesota. The recycled heat kept the metal liquefied for longer than the bessemer process, giving workers more time to add the precise amounts of carbonbearing iron alloys that turned the material to steel. The process is named after its inventor, henry bessemer, who took out a patent on the process in 1855. Methods for manufacturing steel have evolved significantly since industrial production began in the late 19th century. The manufacture of steel nz institute of chemistry.
Wrought iron is quite soft and easily worked and has little structural strength. Nov 12, 2012 a short video clip illustrating the process of iron and steel making that can be viewed online by students or downloaded for showing in class. This section deals with the types of iron and steel which are produced as a result of the steel making process. Amazing automatic melting aluminum manufacturing factory, cast aluminum process using sand mold duration. 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. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. Alloy steel is a mixture of iron ore, chromium, silicon, nickel, carbon and manganese, and it is one of the most versatile metals around. Control of pollution in the iron and steel industry. Scrap steel is charged to begin a cycle, and alloying agents and slag materials are added for refining. Apr 27, 2015 4272015 23 manufacturing process for iron and steel engineering materals ii meng 2122 23. As with all largescale manufacturing processes, the production or iron and steel generates byproducts. Aug 21, 2016 amazing automatic melting aluminum manufacturing factory, cast aluminum process using sand mold duration. Iron and steel industry report deloitte cis manufacturing. Over the last 35 years, the iron and steel industry has seen significant changes.
Doushanov encyclopedia of life support systems eolss prevent, reduce, or eliminate adverse environmental consequences in. Steel obtained from this process is called blister steel due to the blisterlike marks formed on the surface due to the evolved gases during the manufacturing process. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. Ironmaking and steelmaking metallurgical and materials. The former process is based on reduction of iron ore, yielding a highly porous spongeiron which subsequently is comminuted to powder.
Water requirements of the iron and steel industries by faulkner b. Galvanizing process american galvanizers association. There are 57 types of alloy steel, each with properties based on the percentage amount of each element mixed into the alloy. Processes that produce iron by reduction of iron ore in solid state below the melting. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Even though equipment is improved and higher production rates can be achieved, the processes. In the conventional integrated steel manufacturing process, the iron from the blast furnace is. Another cutting method is known as plasma jet cutting, in which an ionized gas column in conjunction with an electric arc through a small orifice makes the cut.
Secondary steelmaking is a refining process in which alloying metals are added and impurities are removed. Smelting reduction technologies cokeovensinterbf route used by integrated steel plants that produce steel from iron ore. It constitutes 5 percent by weight of the earths crust, and it is the. On average the production of 1 tonne of steel results in 200 kg eaf to 400 kg bfbof of byproducts. Sep 18, 2019 cast iron has already been mentioned above.
This oxygen combines with carbon in the iron and carbon is eliminated in the form of carbon di oxide. Hot metal and crude steel process are also inter linked among themselves as represented by arrows. The first involves the production of molten iron and the second is that of actual steel manufacture. Pdf methods of steel manufacturing the electric arc furnace. Ntn is working on the creation of part technologies that realize ecology and economy for various parts of the. The regulation covers any facility that is engaged in iron or steel manufacturing, forming, and finishing, including coke manufacturing. Alloy steel 1 analysis flow measurement radiation leak detection coating weight measurement pinhole detection.
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