WELCOME ALL

NotesStrategic location –Vizag, Andhrapradesh

Established : 1982

5th Rank in the World

Capacity of -252,000 Tons Per year

World Steel Industry – Top Ten

S. Korea53.6 mT

6

Italy30.6 mT

10

8

Ukraine38.6 mTGermany

45.8 mT

7

3

USA91.4 mT

4

Russia 68.5 mT

9

Brazil33.7 mT

5

India58.1 mT

Global crude steel Production: 1326.5 million tonnes(Mt)

1

China502 mT

2

Japan118.7 mT

STEEL MANUFACTURING

WHAT İS STEEL ?In the beginning, there was iron...

Then came cast iron...

...and finally steel

GENERAL ISSUES ABOUT STEEL

• Steel has been called the world’s most useful and inexpensive metal.

• In recent decades ,steel manufactures have been forced to take a much closer look at what their processes have been doing to the fragile environment around them.

WHAT İS STEEL USED FOR - IThe structures such as oil platforms, catalytic converters, paper clips, mounts for electronic chips...are all made of steel.

1. In the construction of bridges or buildings...

2. In the automobile sector for the manufacture of automobile parts

WHAT İS STEEL USED FOR-II3. For everyday uses:

cans,pots,containers,etc...4. At the heart of food

preservation...

5. In communications... 6. In energy... 7. In health...

STEEL PRODUCTSSemi-finished products(continuous cast steel)

Finished products (rolled steel)

STEEL MANUFACTURING PROCESS INFRASTRUCTURE

Coke Ovens And Coal Chemical Plant Sinter Plant Blast Furnace Steel Melt Shop And Continuous Casting LMMM WRM MMSM

CONVERSION OF COAL INTO COKEIt Can Be Achieved By Using Coke Ovens And Coal Chemical Plant

Heating the blended coal charge in absence of air at a temperature of 1000oC-1050oC for a period of 16/19 hours.

Coke ovens

The volatile matter of coal liberated during carbonization is collected in gas collecting mains and cooled with ammonia liquor spray.

The gas cooled from 800oC to 80oC is drawn to Coal Chemical Plant by Exhauster. The residual coke is pushed out of the oven by pusher car through a guide into coke bucket.

The red-hot coke is taken to coke dry cooling plant for cooling.

Ammonium Sulphate (NH4)2SO4 Crude Tar, Crude Benzol and Cleaned coke oven gas.

Cooled Coke from CDCP (Coke Dry Cooling Plant) is separated i into 3 Fractions BF Coke i.e. +25-70mm which is sent to Blast Furnaces

Coke Breeze i.e. +0-15mm which is sent to Sinter making and

Nut coke i.e., +15-25mm, which is also used in the Blast furnace.

Different Cokes Obtained

BY PRODUCTS

HOW İS STEEL MADE-I

STEEL MAKİNG PLANT

Electric Arc Furnace Ladle Furnace Continuous Casting Machine

What is a Blast Furnace?• Blast furnace is used

to reduce and convert iron oxides(ore) 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.

Why does Iron have to be extracted in a Blast Furnace???

• Iron have to be extracted in the blast furnace because it can be displaced by carbon.

• This is more efficient method than electrolysis because it is more cost effective

Three substances are needed to enable to extraction of iron from its ore. The combined mixture is called the CHARGE.Iron ore, haematite - 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 metres high and lined with fireproof bricks. Hot air is blasted through the bottom.

The Method

• Oxygen in the air reacts with coke to give carbon dioxide:

C(s) + O 2(g) CO2(g)

• The limestone breaks down to form carbon dioxide:

CaCO3(s) CO2 (g) + CaO(s)

• Carbon dioxide produced in 1 + 2 react with more coke to produce carbon monoxide:

CO2(g) + C(s) 2CO(g)

Reactions that take place in a BLAST FURNACE

•The carbon monoxide reduces the iron in the ore to give molten iron:

3CO(g) + Fe2O3(s) 2Fe(l) + 3CO2(g)

•The limestone from 2, reacts with the sand to form slag (calcium silicate):

CaO(s) + SiO(s) CaSiO3(l)

• 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 moulds 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.

• Steel is made in steel melting shop in the refractory lined vessels called LD Converters by blowing oxygen through the hot metal bath.

• Steel making is an oxidation process in which oxygen reacts with the carbon in the hot metal and releases large quantities of gas rich in carbon monoxide along with huge amount of dust.

Steel Making Shop (SMS)

• Hot Metal, Steel Scrap and Fluxes such as calcined lime or Dolomite are added as charge to the Convertors.

• The gases released from the converter are collected, cooled, cleaned and recovered for use as fuel in the steel plant.

• The entire molten steel is continuously cast at the radial type continuous casting machines resulting in significant energy conservation and better quality steel.

Steelmaking Flowlines

EAF Process Flow Diagram

Steelmaking made simple

Blast Furnace Oxygen Steelmaking Secondary Steelmaking

Electric Arc Steelmaking Continuous Casting

Iron OreCoal/CokeNatural gasOilElectricity

Steel scrapCoal/CokeElectricityNatural Gas

Steel scrap

STEEL SECTOR