STEEL MAKING PROCESS
21/01/2016
Tata Steel Europe
BAU Strip
Manish Pandey
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Table of Content
Introduction to STEEL………………………………………………………………………………………………………………………………………………5
Uses of steel…………………..………………………………………………………….......………………………………………………………………………6
Steel making process…………………………………………………………………………………..………………………………………....………….......7
Components of Steel Plant and their uses…………………………………………………………………………………………………..……………8
The basic oxygen steel making process.…….……………………………………..……………………………………………………………………12
Casting Process………………………………………………………………………………………………………………………………………………………15
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STEEL
AND
STEEL MAKING PROCESS
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STEEL :
Steel is an alloy of iron, carbon, manganese, nickel, chromium,
vanadium, sulphur and phosphorus. It has carbon content less than pig
iron or cast iron.
Steel is an alloy consisting mostly of iron, with carbon content between
0.02% , 1.7 and 2.04% depending on grade. Carbon is the most cost-
effective alloying material.
Steel is preferred over pig iron or cast iron because pig iron is
•Brittle
•Not ductile, difficult to shape the material to different shapes
In order to prepare steel products like coils, there is requirement of
preparing liquid steel with the correct composition of the constituents.
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USES OF STEEL:
1) Iron and steel are used widely in the construction of roads, railways,
infrastructure and buildings.
2) Most large modern structures, such as stadiums and skyscrapers
are supported by a steel skeleton.
3) In addition to widespread use, in electrical appliances and motor
vehicles, steel is used in a variety of other construction-related
applications, such as bolts, nails, and screws.
4) Other common applications include shipbuilding, oil and gas
pipelines, mining, aerospace, office furniture, steel wool, tools, and
armour in the form of personal vests or vehicle armour.
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STEEL MAKING PROCESS:
It is at the steel plant where the molten steel is prepared from the Raw
materials.
The Raw materials required are:
1) Iron-ore
2) Coal
3) Fluxes
Iron-ore is the main material required for the preparation of molten
steel. The ore contains particular percentage of Fe (Iron) which is
melted and required percentage of carbon is added through burning of
coal.
Coal is burnt with the iron-ore in a specially constructed and
maintained structure known as blast furnace.
The Fluxes such as limestone and manganese are used to remove any
impurities from the iron-ore so that better liquid steel can be collected.
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The steel plant consists of many components and they have their
functionalities:
The main parts are:
Sinter plant
Coke plant
Blast Furnace
LD1
LD2
Hot Liquid Iron (commonly called Hot Metal) is converted to Steel in the
Steel Melting
Shops. Hot Metal from the Blast Furnace is stored in Mixers in LD#1
shop. The Hot
Metal is converted to Steel in the LD converters by removing its carbon,
silicon, sulphur and phosphorous contents.
The liquid steel from the converter is converted to billets using
Continuous Casting machine.
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A small portion of steel is teemed into ingots through Bogie Bottom Poring
process using cast iron moulds.
The liquid steel is treated in on line purging, Ladle Refining Furnace or
Argon Rinsing station before continuous casting.
Special grades of steel, which are cast as ingots, are processed in On-
line purging, followed by the Vacuum Arc degassing & refining unit.
The Steel Melting Shop requires an Oxygen Plant to cater to the
requirement oxygen for steel making.
The Lime Calcining Plant and the Tar Dolo Plant are auxiliary units
required for the manufacture of Steel.
SINTER PLANT:
Sintering is a process in which solid wastes are combined into a porous mass that
can then be added to the blast furnace.
These wastes include iron ore fines, pollution control dust, coke breeze, water
treatment plant sludge, and flux.
Sintering plants help reduce solid waste by combusting waste products and
capturing trace iron present in the mixture.
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COKE PLANT:
Coke is a solid carbon fuel and carbon source used to melt and reduce iron ore.
Coke production begins with pulverized, bituminous coal.
The coal is fed into a coke oven which is sealed and heated to very high
temperatures for 14 to 36 hours.
Coke is produced in batch processes, with multiple coke ovens operating
simultaneously.
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The Blast Furnace is the structure where the raw materials are mixed and
molten steel is prepared.
It is at the blast furnace where the raw materials i.e. iron ore, limestone and coal are
mixed .Iron ore is mixed with oxygen in order to reduce it to iron and coal is
converted to coke in order to melt the iron-ore. The liquid steel is collected from the
openings present at the bottom of the furnace. The impurities present in the iron-ore
are removed by the added flux and the impurities being lighter in weight floats above
the molten iron and is known as slag.
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The Basic OXYGEN STEEL MAKING PROCESS:
Pouring of hot metal from BF into a ladle
Pre treatment
Charging
Oxygen lancing
Addition of fluxes
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In the below given picture the oxygen steel making process is depicted.
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The purpose of steel making is to reduce the carbon in the hot metal
from 4.5% to less than 1.5%.
The steel making consists of three main steps: charging, blowing,
tapping.
The BF is charged with 85% hot metal and balance 15% scrap, some
fluxes such as burnt lime and dolomite and ferrous alloys.
Oxygen is blown into the hot metal at very high speeds. The oxygen
reacts with carbon and silicon to produce CO and other acidic oxides.
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CASTING :
Once the molten steel is prepared, it is collected by ladle and poured into
a big reservoir known as Tundish.
The molten steel from the tundish is poured onto the caster where the
casting of molten steel to steel slabs takes place.
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Thank You
Contact
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