It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium bc iron was being produced from iron ores from at least greece to india, and more. Introduction carbon dioxide exhausted by the iron and steel industry accounts for approximately 15% of the total. Aist is recognized as a global leader in networking, education and sustainability programs for advancing iron and steel technology. Recent progress in ironmaking technology for 2 mitigation at. Mesabi nugget, lcc, a joint venture between steel dynamics and kobe steel, began producing pig iron nuggets using itmk3 technology in january 2010. Meanwhile, a new technology named corex has emerged in this field. The high dome temperature exceeding 1,000 c results in entire cracking of the coals relieved hydrocarbons and avoiding the formation of tar. It is widely distributed, combined with oxygen as iron oxides.
A falling stream of iron ore particles is directly converted to metal in. Development of technologies for treatment of materials charged to blast furnaces. The first blast furnaces appeared in the 14th century and produced one ton per day. Iron age cultures used iron extensively for tools and weapons, rather than relying on earlier technologies such as stone or bronze. The outline of the technology and the effects of application are described. Krakatau steel of indonesia, perwaja steel and lion group of malaysia adopted the technology as they want to make use of inexpensive domestic natural gas as the. In fact it is believed that iron makes up about 5% by weight of the earths crust. The coal is crushed and ground into a powder and then charged into an oven where it is heated to approximately 1800f in the absence of oxygen. Geologists recognise various types of iron ore, classified chiefly according to iron fe content see table 1 below. The earths crust is 5 percent iron, and in some areas, the element concentrates in ores that. For the engineers of primetals technologies, digi talization in steel production starts with genuinely futureoriented ironmaking solutions. As an integral part of developing a novel flash ironmaking technology at the university of utah, the activity of iron oxide in the slag was studied under three different gas atmospheres. The preeminence of these high quality steelmaking operations is being challenged by eafbased mini mills charging varying amounts of aius, primarily pig iron and drihbi, with significant quantities of scrap. To develop computational and mathematical abilities to be applied for process design and control.
The large, refractory lined furnace is charged through its top with iron as ore, pellets, andor sinter. Ironmaking and steelmaking metallurgical and materials. Vss university of technology burla, sambalpur, odisha, india768018 ph. The iron and steel industry has undergone a technological revolution in the last 40 years. The technology significantly improves iron making environmental performance and could well become the iron making technology of choice in the 21st century. Ironmaking provides a vital engineering input in the process of steel production. Archeologists use the term iron age to describe a stage in the technological development of human cultures, not a specific time period.
New iron making processes have been extensively explored with a view to saving resources and energy, as well as reducing environmental pollution. Technology roadmap research program american iron and. During the years of high economic growth from the 1960s to the early 70s, the size of sintering machines was increased to feed large blast furnaces with sintered ore. Emerging technologies for iron and steelmaking springerlink. The earliest surviving iron artifacts, from the 4th millennium bc in egypt, were made from meteoritic ironnickel. The development of new iron making processes, kobelco. The development of iron technology in the mediterranean. It constitutes 5 percent by weight of the earths crust, and it is the. Alternative emerging ironmaking technologies for energy.
It begins by tracing the history of iron and steel production, right from the earlier days to todays world of oxygen steelmaking, electric steelmaking, secondary steelmaking and continuous casting. Direct reduced ironis a process in which iron ore is reduced to the solid state or by gaseous reducing agent. This requires huge investment and hence, selection of an appropriate ironmaking technology is very crucial in a capital scarce country like india. How iron is made material, manufacture, making, history. Development of ironmaking technology nobuhiko takamatsu kiichiro kurihara asao hatanaka genji saitoh hisanori kaku 1. Ironmaking and steelmaking theory and practice and sponge iron production by direct reduction of iron oxide both published by phi learning, new delhi as well as two other books entitled beyond the blast furnace and metallics for steelmaking production and use besides a number of monographs on. That source can often be identified with certainty because of the unique crystalline features widmanstatten patterns of that material, which are preserved when the metal is worked cold or at low temperature. Even though equipment is improved and higher production rates can be achieved, the processes inside the blast furnace remain the same. Finally, there certainly arent any iron shortages to worry about. Ironmaking technology committee association for iron. Alternative ironmaking technologies costly and scarce coking coal. In a relatively short time, the north american industry has observed the complete disappearance of basic open hearth processing, as well as the wide spread adoption of continuous casting and the near complete shift of long product production to the electric arc furnace sector. Iron was extracted from ironnickel alloys, which comprise about 6% of all meteorites that fall on the earth. This authoritative account covers the entire spectrum from iron ore to finished steel.
Corex and finex corex technology is another alternative ironmaking technology. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. Technology of agglomerate production management of agglomeration equipment productivity and agglomerate quality lecture raw materials for production of agglomerate the main purpose of sintering of iron ores agglomeration is to convert fine raw materials. This would remain so probably at least for the first quarter of the century despite speedy depletion of coking coal reserves enhanced adoption of alternate routes for iron making for ultimate conversion to steel. Direct use of fine iron ore the typical iron oxide mix for finex is hematite fine ore with a typical mean grain size of 1 to 2 mm. The blast furnace uses coke, iron ore and limestone to produce pig iron. The blast furnace has been the dominant technology for iron production for centuries. Smelting reduction technology is an alternative technology to the conventional blast furnace. The result will be the worlds first fossilfree steelmaking technology, with virtually no carbon footprint. Kobe steel, a japanese steel company, developed and licensed the itmk3 technology for production of nuggets. 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 physicochemical fundamental concepts of chemical equilibrium, activitycomposition relationships, and. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail.
The basic concepts for reducing emissions based on those calculations are also described. Next, the following are taken up as technologies which were developed in jfe steel based on these concepts. A melter gasifier will turn the lump ore into hot metal and at the same time the reducing gas is produced and piped back to the fluidizedbed reactors. High fraction of lump ore the typical iron oxide mix for corex is 30% lump ore and 70% pellets. This technology achieves reduction, melting, and slag removal in only about 0. The iron age began and ended at different times in. The finex is the latest addition and an optimized fineore smelting reduction sr iron making process based on the direct use of the coal and iron ore fines. Need to look beyond coking coal possibility to use iron ore fines directly landconstraint environmental considerations eliminate pollutionintensive sintering and. American iron and steel institute aisi salt lake city, ut. Steel production american iron and steel institute. Krakatau steel of indonesia, perwaja steel and lion group of malaysia adopted the technology as they want to make use of inexpensive domestic natural gas as the reductant. Finex process is a fluidized bed based process using ore fines instead using iron ore lumps and pellets. Pdf there exist three main ways to produce steel from iron ore, namely integrated route via blast furnace and bof shop, smelting reduction. Pdf the 150 year history of the japanese steel industry dates from the first western blast furnace, which was built by t.
Nov 28, 2017 ferrous extraction iron making overview lecture 1 everything metallurgy. However, in this arena blast furnace bf technology is considered as proven and the dominant one. Hybrit aims to replace coking coal, traditionally needed for orebased steel making, with hydrogen. A comparison of blast furnace and corex routes for iron. A few reasons are analyzed for the apparition and development of such technologies.
Technology of agglomerate production management of agglomeration equipment productivity and agglomerate quality lecture raw materials for production of agglomerate the main purpose of sintering of iron ores agglomeration is to convert fine raw materials into lumpy material for pig iron making in the blast furnace. Pdf recent trends in ironmaking blast furnace technology to mitigate co 2. Historically, iron was produced by the hotblast method, or later, the anthracite furnace. The present scenario of iron and steel sector is very much challenging. Called puddling, this was highly skilled work, but was also hot, strenuous, and dangerous. Rdcis 2 emerging scenario in iron making more than 90% of world iron production is through blast furnace technology route driving forces. This book describes improvements in the iron and steel making process in the. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Direct reduction process is the only ironmaking technology currently adopted in south east asia.
Beneficiation of indian high alumina iron ore fines a case. A falling stream of iron ore particles is directly converted to metal in just seconds using low cost natural gas. Either way, the fundamental activity in iron making involved a worker stirring small batches of pig iron and cinder until the iron separated from the slag. A novel flash ironmaking process department of energy. Geologists recognise various types of iron ore, classified chiefly according to iron fe. The iron age was a period in human history that started between 1200 b. In contrast to most substances, you can also magnetize iron, making it useful in the creation of electric motors and generators. This paper discusses technological transfer diffusion of african sacred ironmaking science into the western hemisphere by enslaved africans. The true objective of the study was to define those alternative ironmaking processes that were lowest in costs while remaining. The high dome temperature exceeds 1,000c, resulting in entire cracking of the coals relieved hydrocarbons and avoiding the formation of tar. The 70 million net tons of steel recycled in 2000 were used to produce about 112 million net tons of new steel in the united states.
Technology roadmap research program american iron and steel. Direct reduction process is the only iron making technology currently adopted in. Need to look beyond coking coal possibility to use iron ore fines directly landconstraint environmental considerations. Conventional technology based on bfbof operations has been the backbone of steel production. In 2016, ssab, lkab and vattenfall joined forces to create hybrit an initiative that endeavors to revolutionize steelmaking.
Recent progress in ironmaking technology for 2 mitigation. The development of iron technology in the mediterranean bronze age contents. Process metallurgy, the science and technology used in the production of metals, employs some of the same unit. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. This requires huge investment and hence, selection of an appropriate iron making technology is very crucial in a capital scarce country like india.
Briquetted or pulverized coal is charged into the meltergasifier. Introduction following the rapid economic growth of japan through the early 1970s, the petroleum crises in 1973 and 1979 caused the economies of developed countries to be sluggish. Direct reduction direct reduction process is the only iron making technology currently adopted in south east asia. The purpose of trp was to save energy, increase competitiveness, and improve the environment. Best available techniques bat reference document for. Cost effectiveness analysis of hyl and drex dri te chnologies for the iron and steelking industry pa ge 7 steel making process and co 2222 emissionsemissionsemissions steel is primarily made by one of two processes. Blast furnace, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed into the top. Co2 generation in the individual processes of the ironmaking process based on the results of calculations for a model steel works2, 3. The hisarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron or hot metal. Kobe steel, along with midrex technologies, is the world leader in direct reduction dr technologies. Dec 14, 2017 iron making provides a vital engineering input in the process of steel production.
This project seeks to demonstrate the scaleup feasibility. Trp differed from other government programs in that the government and industry both contributed research funds. Direct reduction scrap ladle refining electric arc furnace steelmaking iron ore pellets electric arc furnace steelmaking continuous casting design by cover photo. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. A novel ironmaking process is proposed that reduces energy consumption and greenhouse gases compared with blast furnaces and coke ovens. The paper presents few aspects concerning the implementation of alternative iron making technologies in romania. Ferrous metallurgy is the metallurgy of iron and alloys.
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