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IRON MAKING AND STEELMAKING THEORY AND PRACTICE 1st Edition by Ahindra Ghosh ISBN 978-8120332898 812033289X

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IRON MAKING AND STEELMAKING THEORY AND PRACTICE 1st Edition Ghosh Digital Instant Download

Author(s): GHOSH, A.; CHATTERJEE, A.
ISBN(s): 9788120332898, 812033289X
Edition: 1st
File Details: PDF, 6.00 MB
Year: 2008
Language: english
SKU: EB-7302418 Category: Tags: , ,

IRON MAKING AND STEELMAKING THEORY AND PRACTICE 1st Edition by Ahindra Ghosh – Ebook PDF Instant Download/Delivery:  978-8120332898,  812033289X
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Product details: 

ISBN 10:   812033289X

ISBN 13: 978-8120332898

Author: Ahindra Ghosh

IRONMAKING AND STEELMAKING : THEORY AND PRACTICE-PHI-CHATTERJEE, AMIT-2008-EDN-1

Table of contents: 

Part A – GENERAL

1. Introduction

  • 1.1 Early History of Iron (Steel)

    • Meteoric Iron and Wrought Iron

    • Cast Iron

    • Evolution of Ironmaking in Europe

    • Early History of Steelmaking before the Advent of Modern Processes

    • Iron and Steel Heritage of India

  • 1.2 Evolution of Ironmaking Technology Since 1880

    • The Developing Blast Furnace

    • Alternative Ironmaking Processes

  • 1.3 Steelmaking Since Henry Bessemer

    • Bessemer Process

    • Open Hearth Process

    • Electric Furnace Steelmaking

    • Basic Oxygen Steelmaking

    • Secondary Steelmaking and Continuous Casting of Steel

  • 1.4 Present Status of the World Steel Industry

    • Classification

    • World Production of Steel

  • 1.5 Steelmaking in India

  • 1.6 Environmental Pollution and Control

    • Steps Taken by the Steel Industry

    • Forms of Pollution

  • 1.7 Concluding Remarks

  • References

2. Overview of Blast Furnace Ironmaking

  • 2.1 Introduction

    • Improvements Made in Blast Furnace Technology

  • 2.2 Blast Furnace Reactions and Process in a Nutshell

2. Overview of Blast Furnace Ironmaking

  • General Constructional Features of the Furnace

    • Different Regions within a Blast Furnace

    • Size of Blast Furnace

  • Performance of Blast Furnace

  • Blast Furnace Refractory Lining

  • Charging of Solid Materials from the Top

  • Blast Furnace Plant and Accessories

    • Hot Blast Stoves

  • References

3. Overview of Modern Steelmaking

  • Introduction

  • Methods Presently Used for Steel Production

  • Oxygen Steelmaking

    • Top-blown Converter Process

    • Bottom-blown Converters (Q-BOP/OBM)

    • Bath Agitated Processes

  • Electric Steelmaking

    • Electric Arc Furnace (EAF)

    • Electric Induction Furnaces

  • Secondary Steelmaking

    • Ladle Stirring

    • Injection Processes

    • Vacuum Processes

    • Reheating Processes

  • Continuous Casting

4. General Physicochemical Fundamentals

  • Introduction

  • Chemical Equilibrium

    • Activity, Free Energy, Chemical Potential and Equilibrium

    • Free Energy and Equilibrium

    • Oxidation-Reduction Reactions

  • Activity vs. Composition Relationships

    • Introduction

    • Ideal, Non-ideal and Regular Solutions

    • Activities in Molten Slag Solutions

    • Activity-Composition Relationships in Dilute Solutions

  • Structure and Physicochemical Properties of Melts

    • Properties of Liquid Iron and Steel

    • Structure and Physicochemical Properties of Slag Melts

    • Slag Basicity and Capacities

    • Battle Models

  • Kinetics, Mixing and Mass Transfer

    • Introduction

    • Interfacial Chemical Reaction

    • Diffusion

    • Turbulence and Mixing in Fluids

    • Convective Mass Transfer at Interface

    • Enhancement of Process Rates

  • References

Part B – BLAST FURNACE IRONMAKING

5. Physical Chemistry of Blast Furnace Reactions

  • 5.1 Thermodynamics of the Carbon-Oxygen Reaction

    • Combustion of Coke in the Tuyere Zone

    • C–CO–CO₂ Reaction

  • 5.2 Gas–Solid Reaction Equilibria in the Blast Furnace Stack

    • The Fe–O System

    • Thermodynamics of Reduction of Iron Oxides by Carbon Monoxide

    • Dissociation of Limestone

    • Reactions of Hydrogen in the Stack

  • 5.3 Kinetics of Reactions in the Stack

    • Kinetics of Reduction of Iron Oxides by CO and H₂

    • Kinetics of Gasification of Carbon by CO₂

    • Kinetics of Reduction of FeO by Carbon

    • Direct and Indirect Reduction in the Blast Furnace

  • 5.4 Reactions and Phenomena in the Blast Furnace Bosh and Hearth

    • Blast Furnace Slag – Composition and Viscosity

    • Reaction of Silicon

    • Reaction of Sulphur

    • Reactions of Manganese and Titanium

  • References

6. Thermal and Chemical Features of the Blast Furnace

  • 6.1 Introduction

    • Mass and Heat Balances

    • Regionwise Heat and Mass Balances

  • 6.2 Tuyere Flame Temperature

    • RAFT Calculations

    • Tuyere Coal Injection

  • 6.3 Thermal and Chemical Reserve Zones

    • Concept of an Ideal Blast Furnace

    • Reichardt’s Diagram and Thermal Reserve Zone

    • Chemical Reserve Zone

  • 6.4 The Rist Diagram

    • Rist Diagram Based on Oxygen Balance Only

    • Rist Diagram Based on Mass and Heat Balance

    • Rist Diagram Based on Oxygen and Heat Balance, and Fe–FeₓO–Gas Equilibrium

  • References

7. Internal Zones and Gas Flow in Blast Furnaces

  • 7.1 Introduction

  • 7.2 The Six Internal Zones

  • 7.3 Aerodynamic Features of the Granular Zone

    • Ergun Equation for Packed Beds

    • Bed Fluidisation and Elutriation

    • Gas Flow Through the Granular Zone of a Blast Furnace

  • 7.4 Gas Flow in Wet Zones

  • 7.5 Concluding Remarks

  • References

8. Raw Materials I: Coke

  • 8.1 Introduction

    • Availability of Coking Coal

    • Types of Coal Available

  • 8.2 Chemical Characteristics of Coals for Cokemaking

    • Proximate Analysis

    • Ultimate Analysis

  • 8.3 Petrographic Characteristics of Coals for Cokemaking

    • Macerals and Mineral Matter

    • Reflectance (Rank) of Coal

  • 8.4 Other Important Characteristics

  • 8.5 Selection of Coals for Cokemaking

  • 8.6 Assessment of Coke Quality

    • Room Temperature Strength

    • High Temperature Characteristics

  • 8.7 Processes Used for Cokemaking

    • Conventional By-product Coke Ovens

    • Non-recovery Ovens

  • 8.8 Pre-carbonization Techniques

    • Pre-heating of Coal

    • Briquette Blending of Coal

    • Selective Crushing of Coal

    • Stamp-charging

  • 8.9 Alternative Coking Methods

  • References

9. Raw Materials II: Iron Ore and Agglomerates

  • 9.1 Introduction

  • 9.2 Occurrence of Iron Ore

    • Iron Ore Reserves of India

  • 9.3 Beneficiation of Iron Ore

  • 9.4 The Sintermaking Process

    • Bedding and Blending

    • Granulation

    • Sintering

    • Feed Preparation and Product Handling

  • 9.5 Fundamentals of Sintering of Iron Ores

    • Sintering Phenomena

    • Heat Transfer during Sintering

    • Sinter Productivity

    • Structure of Sinter

    • Influence of Sinter Chemistry

  • 9.6 Pelletisation

  • 9.7 Physical and Chemical Characterisation of Lump Ore/Sinter/Pellets

    • Physical Testing

    • Chemical Characterisation

    • Thermal Analysis

9.8 Metallurgical Tests

  • Compression and Tumbler Strength

  • Reduction Behaviour

  • Reducibility

  • Reduction under Load

  • Softening-Melting Test

9.9 Recycling of Materials in the Blast Furnace

  • References

10. Blast Furnace Productivity, Fuel Efficiency and Modern Developments

  • 10.1 Introduction

    • Efficiency of Operation

  • 10.2 Fundamentals of Blast Furnace Productivity

    • The Concept of Productivity

    • Specific Gas Volume Requirement

    • Gas Flow through the Furnace

    • Furnace Irregularities

  • 10.3 Effect of Agglomerated Iron Oxides on Productivity

    • Use of Sinter

    • Use of Pellets in Burden

    • Reducibility

    • Reduction-Degradation Index (RDI)

    • Softening-Melting Characteristics

  • 10.4 Coke Quality for Improved Productivity and Fuel Efficiency

  • 10.5 High Top Pressure (HTP) Operation

    • Influence of HTP on Productivity and Fuel Efficiency

    • Some Other Performance Improvements through Use of HTP

  • 10.6 The Bell-Less Top

  • 10.7 Pulverised Coal Injection (PCI)

  • 10.8 Concluding Remarks

  • References

11. Blast Furnace Products and Their Utilisation

  • 11.1 Introduction

  • 11.2 Composition of Hot Metal

    • Overall Input and Output Considerations

    • Silicon Control

    • Sulphur Control

    • Phosphorus Content of Hot Metal

  • 11.3 Handling Hot Metal and Slag

    • Tapping of Hot Metal and Slag

    • Transportation of Hot Metal

  • 11.4 Blast Furnace Slag and Its Utilisation

    • Slag Characteristics

    • Usage of Blast Furnace Slag

  • 11.5 Blast Furnace Gas and Its Utilisation

    • Cleaning of Blast Furnace Gas

  • Reference

12. Blast Furnace Modelling and Control

  • Introduction

  • General Approach

  • Process Modelling

    • Blast Furnace Models and Their Purpose

    • Types of Models Available

  • Steps Involved in Mathematical Modelling

    • General Formulation

    • Identification of Framework

  • Important Process Models

    • Burden Distribution Model

    • Thermochemical Model

    • Model of the Raceway

    • Freeze-line Model of the Hearth

  • Real-time Process Simulator

  • Reference

Part C: Alternative Ironmaking

13. Sponge Ironmaking

  • Introduction

  • Processes of Making Sponge Iron

  • Properties of Sponge Iron

  • Uses of Sponge Iron

  • Coal-based Sponge Iron Processes

    • Sponge Iron Production in Rotary Kilns

    • Coal-based Processes Using Rotary Hearth Furnaces

  • Gas-based Processes

    • Reforming of Natural Gas

    • Gas-based Direct Reduction in Fluidised Beds – Finmet Process

    • Gas-based Reduction in Stationary Retorts (HYL Process – Now Referred to as HYL I)

    • Gas-based Shaft Furnace Processes

  • Reference

14. Smelting Reduction

  • Introduction

  • Raw Materials for Smelting Reduction

  • Fundamentals of Smelting Reduction

  • History of Smelting Reduction

    • The Early Stages

    • The Second Stage

    • Commercialisation of SR

  • SR Process Categorisation

    • Classification Based on the Number of Stages Involved

    • Classification Based on the Type of Furnace Used for Smelting

  • Salient Features of Important SR Processes

    • Corex Process

    • Hismelt Process

    • Romelt Process

    • Finex Process

    • Fastmelt Process

    • ITmk3

    • Tecnored Process

  • Mini Blast Furnace

  • Reference

Part D: Steelmaking

15. Physical Chemistry of Primary Steelmaking

  • Introduction

  • Reactions and Heat Effects

  • Primary Steelmaking Slags

    • Phase Diagram and Activity-Composition Diagram

    • Other Properties of Primary Steelmaking Slags

  • The Reaction Equilibria

    • Introduction

    • Oxidation of Iron

    • Reactions of Carbon

    • Oxidation of Silicon

    • Reaction of Phosphorus

  • Mass Transfer and Kinetics in Steelmaking

  • References

16. BOF Plant Practice

  • Introduction

  • BOF Operation

  • BOF Shop Layout and Individual Converter Components

    • BOF Vessel Design and Refractory Lining

    • The Lance

    • Gas Cleaning System

    • Engineering Features of BOF Shops

  • Refining

  • Major Inputs for BOF Steelmaking

    • Hot Metal

    • Coolants

    • Flux Materials

    • Oxygen

  • Pre-treatment of Hot Metal Prior to Steelmaking

    • Objectives of Pre-treatment

    • Removal of Silicon

    • Desulphurisation

    • Dephosphorisation

16. BOF Plant Practice

  • Reagents Used for Pre-treatment

    • Soda-ash

    • Mixture of Soda-ash and Sodium Sulphate

    • Mill Scale, Sinter Fines, etc.

    • Calcium Carbide and Magnesium Granules

    • Injection of Desulphurising Agents

  • Hot Metal Pre-treatment Station(s)

    • Desiliconisation

    • Desulphurisation

  • Simultaneous Removal of Sulphur and Phosphorus

  • General Comments on Pre-treatment

  • References

17. Metallurgical Features of Oxygen Steelmaking

  • Introduction

  • Interaction of the Oxygen Jet with the Surroundings and the Bath

    • Mechanical Interactions

    • Chemical Interactions between Jet and Bath

    • Chemical-Thermal Interactions of the Jet with the Surroundings

  • Composition and Temperature Changes During the Blow

    • Slag Path and Lime Dissolution in Slag

    • Kinetics of Lime Dissolution

  • Kinetics of Carbon-Oxygen Reaction in BOF: Slag-Metal-Gas Interaction

    • Foams and Emulsions in Basic Oxygen Steelmaking

    • Mechanism of Carbon-Oxygen Reaction

  • Metallurgical Features of Bath Agitated Processes

    • General

    • Some Process Details

  • Oxygen Bottom Blown Processes

  • Comparison of Various Basic Oxygen Processes in Terms of Composition Control

  • References

18. Process Control for Basic Oxygen Steelmaking

  • Introduction

    • Chronology of Developments

  • Mathematical Models

    • Static Models

    • Dynamic Models

  • Semi-Dynamic Control

    • The Sub-lance

    • Immersion Carbon Sensor

    • Immersion Oxygen Sensor

  • Dynamic Control

    • Measurements on Exit Gas

    • Application of Sonic Meter

  • Concluding Remarks

  • References

19. Basic Open Hearth and Electric Arc Furnace Steelmaking

  • Basic Open Hearth Steelmaking

    • The Open Hearth Furnace

    • Steelmaking in Basic Open Hearth Furnaces

    • Transfer of Oxygen and Heat in Open Hearth Furnaces

    • Concluding Remarks

  • Electric Arc Furnace Steelmaking

    • General

    • The Furnace and the Auxiliaries

    • Conventional EAF Steelmaking Practice

    • Modern Developments in EAF Steelmaking

  • Performance Assessment of EAF Steelmaking

    • Key Process Performance Indices

    • Operating Costs

    • Steel Quality Control in EAF

  • References

20. Secondary Steelmaking

  • Introduction

  • Inert Gas Purging (IGP)

  • Deoxidation of Liquid Steel

    • Thermodynamics of Deoxidation of Molten Steel

    • Kinetics of Deoxidation of Molten Steel

    • The Ladle Furnace (LF)

    • Problem of Slag Carryover

    • The CAS-OB Process

  • Degassing and Decarburisation of Liquid Steel

    • Thermodynamics of Degassing Reactions

    • Kinetics of Desorption and Absorption of Nitrogen by Liquid Steel

    • Vacuum Degassing Processes

    • Manufacture of Ultra-Low Carbon (ULC) Steel by RH-OB Process

  • Desulphurisation in Secondary Steelmaking

    • Thermodynamic Aspects

    • Kinetic Aspects

    • Injection Metallurgy (IM)

  • Clean Steel Technology

    • Introduction

    • Cleanliness Control during Deoxidation

    • Cleanliness Control during Teeming

    • Tundish Metallurgy for Clean Steel

  • Miscellaneous Topics

    • Inclusion Modification

    • Temperature Changes during Secondary Steelmaking

    • Refractories for Secondary Steelmaking

  • References

21. Stainless Steelmaking

  • Introduction

  • Melting and Refining of Stainless Steels for Scrap and Ferroalloy-Based Processes

    • Melting

    • The AOD Converter Process

    • Thermodynamics of Reactions in the AOD Process

  • Other Processes for Stainless Steelmaking

  • Direct Stainless Steelmaking

  • References

Part E: Casting of Liquid Steel

22. Ingot Casting of Steel

  • Introduction

  • Fundamentals of Solidification

    • Heat Transfer and Solidification Rate in Ingot Casting

    • Segregation and Crystallisation during Solidification

  • Classification of Steel Ingots

    • Gas Generation during Freezing

    • Types of Ingots

  • Ingot Defects and Their Remedies

    • Pipe

    • Blow-hole

    • Columnar Structure Effects

    • Segregation

    • Non-metallic Inclusions

    • Internal Fractures and Hairline Cracks

    • Surface Cracks

  • References

23. Continuous Casting of Steel

  • Introduction

  • Heat Transfer and Solidification in Continuous Casting

    • General Considerations

    • Heat Transfer in the Mould

    • Mould Flux

    • Heat Transfer in Secondary Cooling Zone

  • Metallurgical Comparison of Continuous Casting with Ingot Casting

  • Modern Tundish Practice

    • Metallurgical Aspects

    • Tundish Design and Operation for Clean Steel

  • Current State of Continuous Casting Technology for Steel

    • General Features

    • The Mould and Its Operation

    • Electromagnetic Stirring

23. Continuous Casting of Steel

  • Metallurgical Defects and Their Remedies

    • Centreline Macro-segregation and Porosity

    • Cracks

    • Other Defects

  • Some Special Topics

    • Round Caster and Combination Caster

    • High Speed Casting

  • Near-Net Shape Casting

    • Thin Slab Casting

    • Strip Casting

    • Beam Blank Casting

  • References

Part F: Miscellaneous

24. Ironmaking and Steelmaking in India

  • Introduction

  • Evolution of Global/Indian Steel

  • India’s Potential in Steel

  • Growth of the Global Steel Industry

  • Expansion Plans of Indian Steel Producers

  • Raw Materials Scenario in India

    • Coal for Ironmaking

    • Iron Ore Scenario

  • Alternative Ironmaking in India

    • Direct Reduction

    • Smelting Reduction

    • Mini Blast Furnaces (MBFs)

  • Structure of the Indian Steel Industry

    • The Future

    • Concluding Comments

  • References

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