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    Steel Making Process

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    Hari sadu
    The document discusses several steelmaking processes including: 1) The Bessemer process which uses air or oxygen blasted through molten iron to oxidize impurities in 15-20 minutes. 2) The open hearth process which uses heat regeneration to refine scrap and molten pig iron over 6-10 hours. 3) Electric arc furnace steelmaking which uses an electric arc to heat charges over shorter tap to tap times than open hearth. 4) Modern processes like LD converter, KALDO, and Q-BOP which use oxygen blowing to further refine steel in 40-70 minutes.

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    Steel Making Process

    Uploaded by

    Hari sadu
    80 views19 pages
    The document discusses several steelmaking processes including: 1) The Bessemer process which uses air or oxygen blasted through molten iron to oxidize impurities in 15-20 minutes. 2) The open hearth process which uses heat regeneration to refine scrap and molten pig iron over 6-10 hours. 3) Electric arc furnace steelmaking which uses an electric arc to heat charges over shorter tap to tap times than open hearth. 4) Modern processes like LD converter, KALDO, and Q-BOP which use oxygen blowing to further refine steel in 40-70 minutes.

    Original Title

    2. STEEL MAKING PROCESS

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    The document discusses several steelmaking processes including: 1) The Bessemer process which uses air or oxygen blasted through molten iron to oxidize impurities in 15-20 minutes. 2) The open hearth process which uses heat regeneration to refine scrap and molten pig iron over 6-10 hours. 3) Electric arc furnace steelmaking which uses an electric arc to heat charges over shorter tap to tap times than open hearth. 4) Modern processes like LD converter, KALDO, and Q-BOP which use oxygen blowing to further refine steel in 40-70 minutes.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    80 views19 pages

    Steel Making Process

    Uploaded by

    Hari sadu
    The document discusses several steelmaking processes including: 1) The Bessemer process which uses air or oxygen blasted through molten iron to oxidize impurities in 15-20 minutes. 2) The open hearth process which uses heat regeneration to refine scrap and molten pig iron over 6-10 hours. 3) Electric arc furnace steelmaking which uses an electric arc to heat charges over shorter tap to tap times than open hearth. 4) Modern processes like LD converter, KALDO, and Q-BOP which use oxygen blowing to further refine steel in 40-70 minutes.

    Copyright:

    © All Rights Reserved
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 19

    STEEL MAKING

    PROCESSES
    LECTURE 2
    OVERVIEW
    • Steel making a process of selective oxidation of impurities.
    • Exception of sulphur which is reduced.
    • Reverse of Iron Making
    • End product is an alloy rather than Pure metal.
    • Oxides removed either as gas or Liquid oxide product as slag.
    Process Development
    Process in a Steel Making shop
    PROCESSES
    •
    BESSEMER
    • Also known as Thomas process
    • Process Molten Iron in a perforated Bottom called
    Converter.
    • Cold Air/O2 Enriched Blast is forced through the metal
    from Below.
    • Refining Completed in 15-20 mins.
    • Tap to tap time of 30-35 minutes are required.
    • Autogeneous process (No external Heat is needed).
    BESSEMER

    A. K. Chakrabarti, Steelmaking, PHI Learning, 2006.


    CLASSES OF BESSEMER
    • Acid Bessemer

    Usage of Acid Pig Iron i.e. Low in Sulphur and Phosphorous but high
    in silicon.
     Lining is with acid material (ganister or silica bricks)
     Acidic Slag.
    CLASSES OF BESSEMER
    • Basic Bessemer

     Phosphoric Pig Iron with low silicon and Manganese


    Content.
     Lining is with basic material (Calcined Magnesium
    Limestone)
     Basic Slag.
    WHY BESSEMER PROCESS IS
    REPLACED BY OTHER MODERN
    STEELMAKING PROCESS

     Injection of air leads to N2 embrittlement which is highly problematic


    during fabrication of deep drawing products.
     Refining time is very fast, allows less time for compositional
    control/chemical analysis.
     Less efficient for removing phosphorus from hot metal, low
    phosphorus grade ores were very expensive.
     Scrap addition was limited which increases costs.
    OPEN HEARTH
    • Shallow basic lined vessel.
    • Works on principle of Heat regeneration.
    • Steel Making temperature upto 1600-17000C.
    • Charge is scrap + molten pig iron.
    • Basic slag through adding Iron ore+limestone.
    • Tap to tap time = 6-10 h.
    Electric Arc Furnace Steelmaking
    • Steelmaking temperature is maintained by an electric arc struck
    between the electrodes and metallic charge.
    • High costly because of high cost of electricity.
    • Well suited for alloy steels.
    • Small furnace capacity.
    • Cold charges
    Electric Arc

    A. K. Chakrabarti, Steelmaking, PHI Learning, 2006.


    LD Converter Steelmaking
    • Linz Donawitz Process (two places in Austria)
    • Oxygen is blown Vertically.
    • Autogeneous process.
    • Steel scrap usage as coolant.
    • Refining time 20-25 mins.
    • Tap to Tap time = 40-60 mins.
    KALDO
    • Similar to LD converter in design.
    • Furnace is kept inclined to horizontal at an angle of 200.
    • During refining converter is rotated around its own axis.
    • Maximum speed is 30 rpm.
    • Oxygen lance is also inclined to horizontal with an adjustable angle.
    • Refining time = 60-70 mins.

    R. H. Tupkary, V. R. Tupkary, An Introduction to Modern Steel Making


    Khanna Publisher, 2000. 
    LDAC/OLP Linz-Donawitz-Arbed-Centre,
    Oxygen Lime powder
    • Modified LD process developed to replace old Basic Bessemer Process.
    • Refine pig iron more than 1.5% P
    • Lime powder is blown along with Oxygen in order to accelerate the phosphorous
    removal process.
    • Vessel design is same to that of LD but lance design is different to facilitate supply of
    oxygen and lime together.
    Q-BOP/OBM
    • Developed from difficulties of top oxygen blowing in LD process
    and fascination for simplier design of Bessemer process.
    • Oxygen is blown from the tuyere at the bottom of the vessel.
    • Developed to refine Thomas grade iron but can refine ordinary
    basic iron also.
    • Tap to Tap time is 40 mins.
    Hybrid Blowing/ Combined Blowing
    process
    • Developed from both problem faced in refining top blowing in LD and bottom blowing in OBM process.
    • Top lance : Oxygen+Lime
    • Bottom : bath agitation gas. (Nitrogen/Argon gas)(3% of O2)
    • Hybrid blowing
     eliminates temp/ Concentration gradients effects
     improves blowing control
     high blowing rates,
     reduces over oxidation,
     improves yield
     Effective desulphurization and dephosphorization for making low carbon steel.
    Modified Conventional process
    • Modification of Conventional Bessemer process.
    • Usage of Oxygen during melting and refining to decrease tap to tap time.
    • Tap to tap time decreases from 12-16 hours to 4 hours.
    • Oxygen lancing is done vertically through the roof or through the end wall at an angle. (Ajax Process)
    • Oxygen as refining agent: Tandem furnace, Twin Hearth.

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