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Methods, Processes and Equipment Involved in Manufacturing Steel

The document outlines the key steps in the steel manufacturing process: 1) Carbonization of coke from coal, which is then fed into the blast furnace. 2) In the blast furnace, iron ore, limestone, and coke are introduced, and air is blown in to reduce the iron oxides into liquid pig iron. 3) In basic oxygen steelmaking, carbon and other impurities are reduced from the pig iron by injecting oxygen and adding scrap metal and slag removal produces liquid steel.

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Niño Gerard Jabagat
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123 views22 pages

Methods, Processes and Equipment Involved in Manufacturing Steel

The document outlines the key steps in the steel manufacturing process: 1) Carbonization of coke from coal, which is then fed into the blast furnace. 2) In the blast furnace, iron ore, limestone, and coke are introduced, and air is blown in to reduce the iron oxides into liquid pig iron. 3) In basic oxygen steelmaking, carbon and other impurities are reduced from the pig iron by injecting oxygen and adding scrap metal and slag removal produces liquid steel.

Uploaded by

Niño Gerard Jabagat
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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MANUFACTURING OF

STEEL
Process involved in manufacturing

• Carbonization of COKE
• Blast furnace
• Basic Oxygen Steel making [BOS]
• Electric arc method
First stage

Preparing the mineral of iron. It starts in the mine or quarry, where


it´s obtained in nature is a rock with iron, oxide, dirt and other
impurities.
1. Carbonization of COKE

The impurities are removed in the first part of the process, when de gangue
is separated from the ore.

• 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.
Coke
Second Process

The preparing the mineral of iron is:


• The mineral is washed to remove dirt.
• It´s crushed into sand.
•The sand is sieved, and then, again separated from the ore.
Second stage

The blast furnace Lime stone, coke and ore are introduced.
2. What is a Blast Furnace?

• The purpose of a blast furnace is to reduce and convert iron oxides


into liquid iron called "hot metal".
• The blast furnace is a huge, steel stack lined with refractory brick.
• Iron ore, coke and limestone are put into the top, and preheated
air is blown into the bottom.
The lower part of the blast furnace is called crucible. Melted
minerals precipitate on it. Pig iron accumulates at the bottom and
the slag stays above it. They are separated, the pig iron is the
usable part. The pig iron usually cool in molds, after, they are
transported to steel companies.

PROBLEM: The pig iron contains too much carbon and impurities in the
composition. Needs to be reduced before becoming steel.
Why does Iron have to be extracted in a Blast
Furnace?

• Iron can be extracted by the blast furnace because it can be


displaced by carbon.
• This is more efficient method than electrolysis because it is more
cost effective
• Here the continues process can be achieved, i.e. Till the
deterioration of refractory bricks occurs (nearly about 10 years)
Method

Three substances are needed to enable to extraction of iron from its


ore. The combined mixture is called the charge: Iron ore, hematite -
often contains sand with iron oxide, Fe2O3. Limestone (calcium
carbonate). Coke - mainly carbon. The charge is placed a giant
chimney called a Blast furnace. The blast furnace is around 30
meters high and lined with fireproof bricks. Hot air is blasted
through the bottom.
• Both the slag and iron are drained from the bottom of the furnace.
The slag is mainly used to build roads.
• The iron whilst molten is poured into molds and left to solidify -
this is called cast iron and is used to make railings and storage
tanks.
• The rest of the iron is used to make steel.
3. Basic oxygen steel making
Third stage

The carbon and other impurities are reduce inside the converter.
3. Basic Oxygen Steel making (BOS)

Hot metal from the blast furnace and steel scrap are the principal
materials used in
• Modern furnaces, or ‘converters’ will take a charge of up to 350 tonnes
and convert it into steel in around 15 minutes.
• A water-cooled oxygen lance is lowered into the converter and high-
purity oxygen is blown on to the metal at very high pressure.
• The oxygen combines with carbon and other unwanted elements,
eliminating them from the molten charge.
• These oxidation reactions produce heat, and the temperature of the
metal is controlled by the quantity of added scrap.
• The carbon leaves the converter as a gas, carbon monoxide,
which can, after cleaning, be collected for re-use as a fuel.
• lime is added as a flux to help carry off the other oxidized
impurities as a floating layer of slag .
• the converter is tilted and the steel is tapped into a ladle.
Typically, the carbon content of the steel at the end of
refining is about 0.04%.
Scrap is added to the pig iron, so the scrap is recycled. Oxygen is
injected in order to burn the carbon and eliminate the impurities.
After, slag is remove. And the liquid Steel is ready to get the final
shape.
Electric Arc Method
• uses only cold scrap metal.
• employed in making more widely used steels, including alloy and
stainless grades as well as some special carbon and low-alloy
steels.
• Modern electric arc furnaces can make up to 150 tonnes of steel in
a single melt.
• The electric arc furnace consists of a circular bath with a movable
roof, through which three graphite electrodes can be raised or
lowered.
• At the start of the process, the electrodes are withdrawn and the
roof swung clear. The steel scrap is then charged into the furnace
from a large steel basket lowered from an overhead travelling
crane.
• When charging is complete, the roof is swung back into position
and the electrodes lowered into the furnace.
• A powerful electric current is passed through the charge, an arc is
created, and the heat generated melts the scrap.
• Lime and fluorspar are added as fluxes and oxygen is blown into
the melt. As a result, impurities in the metal combine to form a
liquid slag.

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