Primary steelmaking process pdf

Strong economy progress in china followed by strong industrialization. Fundamentals of iron and steelmaking 39 equal to its heat of formation, but of opposite sign. Basic oxygen steelmaking is a method of primary steelmaking in which carbonrich molten pig iron is converted into steel. Steelmaking is the process for producing steel from iron ore and scrap. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo.

This process is also called as basic oxygen process. In the steelmaking process that uses an electric arc furnace, the primary raw material is scrap metal. The first metallurgical step is to reduce iron ore to metallic iron, a. External arc heating permits better thermal control than does the basic oxygen process, in which heating is accomplished by the. The oxygen steelmaking process is a generic name given to those processes in which gaseous oxygen is used as the primary agent for autothermic generation of heat as a result of the oxidation of dissolved impurities like carbon, silicon, manganese and phosphorus and to a limited extent the oxidation of iron itself.

Other byproducts, such as tar, are also extracted for. More than half the worlds steel is produced in the basic oxygen process bop, which uses pure oxygen to convert a charge of liquid blastfurnace iron and scrap into steel. Fullline secondary metallurgy solutions primetals technologies. Primary steelmaking, ladle metallurgy, ingot casting, continuous casting. Steelmaking is the process of producing steel from iron ore andor scrap.

Steelmaking the majority of the bos process usually occurs in large steel. This module introduces the learner to the critical step of refining the chemistry of the steel in order to impart the desired properties required for the grade of steel being produced. A jet of highpurity gaseous oxygen is then directed onto the surface of the liquid metal in order to refine it. To switch the approximately 30 million tons per annum of steel produced via the primary route in germany to h 2based shaft furnace direct reduction would require. The first blast furnaces appeared in the 14th century and produced one ton per day. Secondary refining for purposes of this article, secondary refining or secondary metallurgy is defined as any post steelmaking process performed at a separate station prior to casting and hot metal desulfurizaion. Commodity summary the iron and steel industry, including primary and secondary producer s, is composed of 79 companie s that produce raw steel at 116 locations. This prevents landfill waste, reduces co 2 emissions and helps preserve natural resources. It does not include normal alloying prac tice in the furnace or at the ladle during tapping. The research started by potential study on increasing energy efficiency and carbon dioxide reduction due to integration of.

Therefore, when we want to use a scrap, in eaf process, or even in the bof process, how effectively copper and tin and some other tramp elements can be removed, this is a big issue. In principle, steelmaking is a melting, purifying, and alloying process carried out at approximately 1,600 c 2,900 f in molten conditions. A simplistic overview of the steelmaking process from iron ore to car body manufacturing is followed by an. High flexibility due to hydrogen and hbi storage, and varying scrap charge. Basic oxygen steelmaking bos, bop, bof, or osm, also known as linzdonawitzsteelmaking or the oxygen converter process is a method of primary steelmaking in which carbonrich molten pig iron is made into steel. Even though equipment is improved and higher production rates can be achieved, the processes. Modern steelmaking processes can be divided into two categories. Steel is produced using primary or secondary methods, as shown in figure 2. As the production process varies at this stage depending on the type of steel being made, the resulting slags also have diverse chemical properties making them more difficult to use than ironmaking slags. The bos method adds recycled scrap steel to the molten iron in a converter. This oneofakind experience allows you to click on each phase of steelmaking and provides a deeper. Turkdogan, et, fundamentals of steelmaking, the institute of materials. Thus, a thorough understanding of foams and the foaming process is necessary to optimize the process by minimizing the slag foaming. Assessment of hydrogen direct reduction for fossilfree.

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. Synthesizing the science and its technology, the author examines the relevant reactions and phenomena, presents an integrated picture of clean steel manufacture, and provides an. Hisarna process is more effective and energyefficient. After leaving the coke oven chambers, the raw coke oven gas is. The process was the result of a joint research and development project between siemens metals technologies and dorrenberg edelstahl. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom hotrolled and coldrolled strip coils structural shapes.

The process is known as basic because fluxes of burnt lime or. The primary processes covered by this note are sinter production, pelletising, blast furnace iron making, desulphurisation, basic oxygen and electric arc steel. Various chemical reactions are initiated, either in sequence or simultaneously, in order to arrive at specified chemical compositions and temperatures. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Now, this shows schematic operation of eaf process. 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. Primary measures for reduced so2 emissions from the sinter process. Jun 21, 2016 apart from secondary steelmaking process, there is hisarna steelmaking process which goes under primary steelmaking. Steel making ali altun process metallurgy 060110292 bilal demir 060100281 dogan arslan 060301.

The openhearth process was prevalent in the united states between 1908 and 1969, but it is no longer in use domestically. Bof technology is used for primary steelmaking, and ladle. Mathieson 0 1 2 3 4 henk reimink 0 1 2 3 4 0 present address. Steel rolling technology handbook 2nd revised edition.

Modern steelmaking can be broken down into six steps. Ld process is a refining process which is carried out in a ld vesselor ld converterbof. Globally, the main two primary steelmaking furnaces are oxygen blowing converter and electric arc furnace aod converter from the author side is considered as secondary metallurgy equipment. It also uses liquid steel from an electric arc furnace eaf or any other similar primary steel making furnace. The gas produced during carbonization is extracted and used for fuel elsewhere in the steelworks. Steel is primarily produced using one of two methods. The hisarna steelmaking process is a process of primary steelmaking in which iron ore is processed almost directly into steel.

Revert or home scrap scrap generated during the steelmaking process, e. Before undertaking a detailed study of the processes involved in steelmaking, it is. What is the difference between a primary steel and a. The most common conventional primary production route is based on the blast furnace bf in combination with the basic oxygen furnace bof, which accounts for over 70% of the worldwide steel production world steel association, 2014. During the crimean war, bessemer invented a new type of artillery shell. In iron ore, iron is presents in its oxidised form. A primary steelmaking process refers to the actual process of taking the raw materials and converting them to steel steelmaking. The second principle is that discovered by hess 1840. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into steel.

Our steel is at the heart of the modern world, forming the fabric of life tegrating processing steps and bring ing them under computer. Indeed, many of the reactions interfere with one another, requiring. Iron is generally produced from iron ore t aconite in a primary mineral production process, while steel is produced using both primary and secondary processes. In some converters oxygen is blown through the bottom and the process is. All process steps which are possible in vd and vod plants can be economically carried out with the vld plant, even the production of special and stainless steel grades. In essence, all primary iron and steel production processes are based on the same chemical reactions. Pdf introduction to the production of clean steel researchgate. A secondary steelmaking process refers to operations that refine the crude steel before converting the liquid steel into a solid. Variations and combinations of production routes also exist. Mar 19, 2015 clu refers to the creusotloire uddeholm process. Apart from secondary steelmaking process, there is hisarna steelmaking process which goes under primary steelmaking. To switch the approximately 30 million tons per annum of steel produced via the primary route in germany to h 2. Traditionally, the uninterrupted operation of the steelmaking process is the sole responsibility of the operator, which is recently surpassed by models developed via.

Steelmaking process an overview sciencedirect topics. Low emission steelmaking sharif jahanshahi 0 1 2 3 4 john g. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon are removed from the raw iron, and alloying elements such as manganese, nickel, chromium and vanadium are added to produce different grades of steel. The major development of the clu process was the idea to use superheated steam as the diluting gas instead of argon ar gas which is used in the aod process. The generals reported that the castiron cannons of the time were not strong enough to deal with the forces of the more powerful shell so bessemer. Secondary refining american iron and steel institute.

Pdf this paper introduces the concept of clean steel production from a. Pdf partial carbon capture an opportunity to decarbonize. Academic materials for the economics and management of industrial systems study programme at the faculty of metallurgy and materials engineering. This volatile matter leaves the coke oven chambers as hot, raw coke oven gas. For integrated steelmaking, the primary sources of ghg emissions are blast furnace stoves 43 percent, miscellaneous combustion sources burning natural gas and process gases 30 percent, other process units 15 percent, and indirect emissions from electricity usage 12 percent. It will be a standard reference book for professionals, entrepreneurs, those studying and researching in this. Primary mill fabrication 3 by heating coal to expel the organic matter and gases. You will take charge of a ladle of molten steel from the basic oxygen furnace bof, and attempt to deliver it to the appropriate caster at the specified time, composition, temperature and inclusion content cleanness. In a process called carbonization, blended coal is first heated in ovens to produce coke. This is a modern steelmaking process by which a molten charge of pigiron and steel scrap with alloying elements is contained in a basic lined converter. A process design for hydrogen direct reduction hdr steelmaking is proposed. An introduction to the bof process bof basic oxygen furnaces or basic oxygen steelmaking contributes to the vast majority of world steel production. Once scrap is collected and delivered into the steel making plant, then this scrap is charged into electric arc furnace, then this roof with electrode covers electric arc furnace. Mar 23, 2019 let me answer it in short and simple words.

The process is based on a new type of blast furnace called a cyclone converter furnace, which makes it possible to skip the process of manufacturing pig iron pellets, a necessary step in the basic oxygen steelmaking. It generates revenues for steel producers and forms the base of a lucrative worldwide. Slag foaming practice in the steelmaking process a. 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 process is on a cyclone converter furnace a new type of blast furnace. Indeed, many of the reactions interfere with one another. How steel is made using the basic oxygen steelmaking process. Continuous optical temperature measurement in primary. In the process of converting coal into coke using the byproduct coke oven, the volatile matter in the coal is vaporized and driven off. The sale of these coproducts is also economically sustainable. Competitive production cost at low electricity and moderate carbon prices.

This overview is confined to primary st eelmaking and the permanent storage of co 2 in the. Recovered coproducts can be reused during the steelmaking process or sold for use by other industries. Secondary steel making processes linkedin slideshare. In the first step, the raw inputs iron ore, coke, and lime are melted in a blast furnace. The story of the bessemer steelmaking process is a classic example of the military impetus for technological development. The scrap metal is melted and refined using electrical energy. Control of ascast microstructure morphology of high silicon electrical steels produced through a horizontal belt casting process simulator slater et al.

Steelmaking slag bof and eaf is cooled similarly to aircooled bf slag and is used for most of the same purposes. Bos basic oxygen furnace and the more modern eaf electric arc furnace methods. In this study, through different steps a model is developed for primary steelmaking, with the finnish steel sector as a reference, to evaluate future operation concepts of a steelmaking site regarding sustainability. In principle, steelmaking is a melting, purifying, and alloying process carried out at approximately 1600 c 2900 f in. In this simulation you will play the role of plant metallurgist in charge of secondary steelmaking operations. The resulting molten iron also referred to as hot metal still. It is a revolutionary method for providing continuous temperature measurement and is suitable for many molten metal applications. The basic oxygen furnace bof is a refractorylined, tiltable converter into which a vertically movable, watercooled lance is inserted to blow oxygen through nozzles at supersonic velocity. The secondary steelmaking module is part of the steel manufacturing course. About onequarter of the worlds steel is produced by the electricarc method, which uses highcurrent electric arcs to melt steel scrap and convert it into liquid steel of a specified chemical composition and temperature. The name ld stands for linz and donawitz, these were the two places in austria where the process was born. Modern methods, however, are still based the same premise as the bessemer process, namely, how to most efficiently use oxygen to lower the carbon content in iron. Here all secondary metallurgical work takes place, including deslagging and reslagging, electrical heating, chemical heating or cooling with scrap, powder injection or wire feeding, and stirring with gas.

The drive in recent years by the iron and steelmaking industry to cut costs and still produce high quality steels has illuminated the importance of good slag practices in primary and secondary steelmaking processes. Secondary metallurgy solutions from primetals technologies stands for fully integrated technology, mechanical engineering, automation and electrical engineering from a single source. This is the basis for maximum plant availability, short chargecycle times, low. Introduction the drive in recent years by the iron and steelmaking industry to cut costs and still produce high quality steels, has illuminated the importance of good slag practices in primary and secondary steelmaking processes. The blast furnace is the first step in producing steel from iron oxides. An opentopped cylindrical container made of heavy steel plates and lined with refractory, the ladle is used for holding and transporting liquid steel. Arcelormittal is the worlds leading steel and mining company. Numerical simulation of slag foaming with reaction kinetics. A full transition is only achievable through high capex and a plentiful supply of green electricity. There has been a gradual realization that the slag phase in steelmaking is. The process is known as basic due to the chemical nature of the refractoriescalcium oxide and magnesium oxidethat line the vessel to withstand the high. At high temperatures, oxygen is blown through the metal, which reduces the carbon content to between 01. The process duration varies with the injection rate, hot metal chemistry, and desired final sulfur content, and is in the range of 5 to 30 minutes.

The ba sic oxygen process has sup planted it as the predomina nt primary steelmaking process, making up approximately 95 percent of domestic primary. During melting, oxidation of phosphorus, silicon, manganese, carbon, and other materials occurs, and a slag containing some of these oxidation products forms on top of the molten. Steelmaking and refining introduction to chemistry. In this method, steel is produced directly from iron ore. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into lowcarbon steel.