Over-view of

Iron & Steel Making

Mr. Bhavesh C. Lad
Sr. Manager, Technology Group
THEIS PRECISION STEEL INDIA PVT. LTD
 Contents
1. History of iron making
2. Flow diagram of iron making to steel making
3. Different Section of Iron making
4. Basics of Blast Furnace (Introduction to blast furnace)
5. History of Steel Making
6. Introduction of Steel Making Furnaces
7. Ladle treatment / degassing treatment
8. Continuous casting process
9. Hot rolling
  History of Iron making :

1. 3500BC Beads in Ancient Egypt for iron.

2. First Iron Production 3000BC Syria and Mesopotamia
the comparatively advanced technique of hardening iron
weapons by heat treatment was known to the Greeks
about 1000 BC.
3. They were made by heating a mass of iron ore and
charcoal in a forge or furnace having a forced draft.
4. The iron produced under these conditions usually
contained about 3 percent of slag particles and 0.1 percent
of other impurities. Occasionally this technique of
iron`making produced, by accident, a true steel rather than
wrought iron.
5. Ironworkers learned to make steel by heating wrought
iron and charcoal in clay boxes for a period of several
days. By this process the iron absorbed enough carbon to
become a true steel.

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  General flow diagram of Iron – Steel making process :

Iron making Steel making Continuous casting Rolling Main products

Rail
Sheet pile
Shape
Pellet Coke Section mill Bar

Wire rod
Iron ore Sintered Limestone
ore Wire rod mill

Plate
Hot
direct Plate mill
Billet rolling
Hot metal Hot rolled coil
(HDR)
and sheet
Hot strip mill
Basic oxygen furnace
(BOF) Bloom
Cold rolled coil
and sheet
(also for plating)
Slab Cold rolling tandem mill
Blast furnace
(BF) Welded pipe
Butt welded pipe
Welded pipe mill
Scrap Electric arc furnace
(EAF) Seamless pip
Seamless pipe mill
Reheating furnace
Steel casting

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 Different section of blast furnace plant :

Bell Less Top

Sinter Coke
Gas Cleaning
Hot Blast Stoves
Stock House Gasholder

Scrubber

Enrichment Gas
Combustion Air Slag, Hot Metal

Blower

Combustion Gas

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 Operation Over-View :
Top Gas Mains

The Blast Furnace Process

1.   The Iron Ore, Coke and Limestone, (the Charge), is
conveyed to the top of the Furnace.
Top Bins

2.   The Charge is stored in Bells until the timing is right

for the charge to be dropped into the Furnace.

3.   Hot air is then blown through pipes called Tuyeres,

to fire the mixture.
Throat Armour Above Burden
Probe 4.   The Coke burns to increase the temperature in the
Furnace.
Temperature
Probe
Refractory Lining 5.   The Limestone attracts the impurities in the Iron Ore
Sub Burden Probe and forms Slag. This Slag is lighter than the molten Iron
and so floats on top of it.

Bustle Main 6.   As the Furnace fills, the molten Iron is Tapped off.
The Slag is also tapped off at regular intervals.
Tuyeres
Most Iron is taken straight from the Blast Furnace to the
Hearth Steel Mill, but some is poured into buckets called Pigs.
Refractories This Iron is called Pig Iron and is used to make Cast
Iron.

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  Raw Material for Blast Furnace : Hematite Fe2O3 Limonite Fe2O3. xH2O

Magnetite Fe3O4 Siderite FeCO3

Iron Fe content : 20 - 70%

Ore
SiO2 Al2O3 CaO MgO P, As

S - unwanted, less than 0,15%

Flux Lime, dolomite CaMgCO3 , CaO

Coke Metallurgical coke

Hot Air / Gas Coke oven / Blast Furnace Gas / Hot Air

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  Schematic diagram of B/F :

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  Main reactions in blast furnace :

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 Avg. Input for 1 T Iron Production with Chemistry

Coke Flux Ore

0.35 – 0.6t 0.4t 2t

Chemical composition

Fe C Si Mn P S

90-95% 3.0-4.3% 0.5-3.0% 0.5-3.0% 0.05-2% do 0.1%

Hot Gases
3.5 t Gas

1t Pig Iron

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  Product of Blast Furnace
Pig Iron is being casted to

TORPEDO LADLE
ingot

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  Other Product of Blast Furnace
Chemical composition

MgO, MnO, FeO, CaS,

SiO2 CaO Al2O3
MnS, P2O5, BaS, atd.
Slags
26-40% 36-48% 10-20% negligible

Chemical composition

CO2 CO H2 CH4 N2
Stock gas 8-14% 23-32% 0,2-0,4% 55-60%
1-4%

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  History of Steel making :

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  Introduction of Steel making furnaces :

- There are three core root for production of steel.

1. Open Hearth Process

2. Basic Oxygen Process

3. Electric Arc Furnace

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  Open Hearth Process :

•The Converter
•Melted high carbon iron (pig iron) + bottom injected air
•Fast reaction:
[Fe-C] + {O2 } → [Fe] + {CO }
Minor reaction :
[Fe] + {O2 } → (FeO)
•Liquid steel product
•SiO2 lining (acidic)
•Melted iron (pig iron + scrap) + hot air + flue gas
+ magnesite lining + CaO powder

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  Basic Oxygen Process:

• Liquid pig iron from blast furnace 30-40%

(higher content of C, Si, P, S,…)
• Steel scrap 60-70%
(variable composition - also
Cu, Zn, Pb, Cd,…)
• Iron from direct reduction process (bloom,
sponge, briquettes – quite pure Fe) < 10%

[Fe-C] + {O2 } → [Fe] + {CO }

[Fe-P-S-Si] + {O2 } + <CaO> → [Fe] + (P,S,Si in slag)

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 Operation over-view of Basic Oxygen Process:

Scrap BOS
Liquid Steel batch 200 000 kg
O2 : 500 normal m3/min
steel 20 min
Superficial velocity 1.5 m/s
250 vvm
Gas power input 60 kW/m (or 8 W/kg)
3

Ladle Oxygen
Mixing time 10-100 s

Whole cycle 50 min

Lance

Oxygen tuyere

Steel Slag
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 Electric Arc Furnace :

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 Ladle Treatment :

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 Ladle / Tundish Treatment :

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 Continues Casting of Steel:

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 Continues Casting of Steel:

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 Hot rolling of steel:

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 Hot rolling Product :

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Thank You….for attention

Any Questions….??