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MM3020: Iron making and steelmaking (2012-13-II)
Instructor In charge: Dr. Ajay Kumar ShuklaDepartment of
Metallurgical and Materials EngineeringIIT Madras, India
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Learning Objectives To apply the principles of physical
chemistry and transport
phenomena (heat, mass and momentum) to the process steps in
Ironand Steelmaking as practiced in integrated steel plants.
Be able to understand basic layout of blast furnace, steelmaking
shop and continuous casting process.
To develop computational and mathematical abilities to be
applied for process design and control. It may be C++, MATLAB,
Excel-Solver, FlowBal, FactSage or any other language of
interest.
Be able to model, optimize and control various reactors involved
in steel plant supply chain.
Be able to function in an integrated steel plant/corporate
center and R&D ventures
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Text books: • Ironmaking and Steelmaking: Theory vs. Practice:
Ahindra Ghosh and Amit
Chatterjee• Principles of Blast Furnace Ironmaking: A.K. Biswas•
Fundamentals of Steelmaking Metallurgy: Brahma Deo, Rob Boom•
Fundamentals of Steelmaking: E.T. Turkdogan• Physical Chemistry of
melts in Metallurgy: F.D. Richardson Marks distribution (All exam
problems will be computational in nature)• Quiz 1: 10%• Quiz 2:
10%• Assignments: 20%• Term project: 10%• Final Exam: 50%
Assignments
One every week. Students may use computer coding/techniques to
solve them. It is advised to solve the assignment problems by their
own if want to perform well in exams.
Attendance• There is no weightage for the attendance.• Since the
course involves a lot of computational work and fundamental
understanding about various principles which would be difficult
to understand for those who miss the classes. It would be in the
interest of the all the students to attend all the classes if they
want to score enough to pass the course.
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What is steel ? Steel is a metallic material. Metals are
classified in two categories:
Ferrous vs Non-Ferrous
Steel is Fe+C+……….
It is subsequently catagorized as plain carbon steel and alloy
steel
Plain carbon steel: Low carbon (C< 0.3%, Medium carbon
(0.3-0.6%), High Carbon(0.6-1.0%)
Plain carbon steel contains C, Si, Mn, S, P, N, O ,H… as
dissolved elements.
Alloy steels contains other elements in addition to them
depending upon requirements like Ni, Cr, Nb, Co, Ti ,B, Mo,W
etc.
Steel exhibits a wide range of mechanical properties depending
upon its composition and heating-cooling cycles
(Heat-treatment)
Knowledge of Fe-C phase diagram, CCT, TTT is required to predict
the desired processing in order to obtain desired microstructure
forspecific mechanical properties
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Fe-C, TTT an CCT diagramCourtesy: msm.co.uk
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Applications of steel Steel is the most widely used material in
the world in Automative,
Construction, Engineering, Packaging and Offshore
application
Usage comparison (yearly)Steel: 1400 MT, Aluminum : 40 MT,
Copper: 16 MT, Zinc: 10.6 MT, Lead 7 MT, Nickel: 1.7 MT, Magnesium:
0.8 MT, Titanium: 0.15 MT
Low carbon steel application: Flat rolled products like
Automobiles, Seamless tubes
Medium carbon steel application: Shafts, coupling, crank
shafts
High carbon steels: springs, high tension wires
Suggested readings: www.steeluniversity.org,
www.worldsteel.org
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Worldwide steel production and India's position
In 2011 total steel production of entire world was 1490 MT.
India produced 72 MT (5% contribution).
Per capita steel consumption is the index of prosperity of any
country. World per capita steel consumption is 215 kg. India has
approx. 50 kg per capita consumption.
India has projected to produce 140 MT by end of 2016-17.
China with same population as India is producing 683 MT (highest
in world).
India has to go up to 1000 MT with current population in order
to be ranked in developed nations.
Therefore Steel industry is a booming industry for next 30-40
years in India.
More information on world statistics of steel production please
go through : www.worldsteel.org and website of planning commission
india
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Iron and Steelmaking process routes
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What is needed to know: Layout of the entire plant and design
aspects of the
processes Physicochemical aspects of the process:• Type of
reactions• Thermodynamics and equilibrium systems of
importance• Kinetics, heat and mass transfer Phase diagrams
(esp. for slag systems) Raw materials properties Process control
models: Static vs Dynamic vs Data
driven Optimization of a process or entire steel plant
supply
chain (with objective of minimum cost/maximum profit)
Automation control hierarchy of large scale steel plant
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Blast furnace ironmaking
• Carbothermic reduction of iron ore (Hametite) in blast furnace
is a well known process. Overall process is written as:
• Ironore oxide mineral + gangue + Reducer (C) + flux + hot
blast oxygen enriched air = Pig iron (liquid) + Slag (liquid) +
waste gas (CO,CO2,N2)
• Iron ore contains Fe2O3, along with gangue materials such as
SiO2, Al2O3.
• Charge materials are: Iron ore + limestone (flux) + Coke•
Output is
pig iron (1300 C), 4.5% C, 0.4-0.6% Si, 0.1-0.2% P, 0.040-0.050%
S, 0.1-0.5% MnSlag: CaO/SiO2 = 1.1; CaO = 30-40%; Al2O3 = 10-23%;
FeO
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Blast furnace layout with auxillaryequipments
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Reaction zones in a blast furnace
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a) Gas temperature along stackb) Reduction zones along stackc)
Carbon reduction degree (O/Fe) with stack height
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Chemical reactions in a blast furnace
Zone 1 (1050 C.
