IRONMAKING and THEORY AND PRACTICE. Ahindra Ghosh Amit Chatterjee

Transcription

1 IRONMAKING and STEELMAKING THEORY AND PRACTICE Ahindra Ghosh Amit Chatterjee

2 IRONMAKING AND STEELMAKING

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4 IRONMAKING AND STEELMAKING Theory and Practice AHINDRA GHOSH Formerly Professor Materials and Metallurgical Engineering Indian Institute of Technology Kanpur AMIT CHATTERJEE Formerly Chief Technology Officer Currently Adviser to the Managing Director Tata Steel Limited, Jamshedpur New Delhi

5 IRONMAKING AND STEELMAKING: Theory and Practice Ahindra Ghosh and Amit Chatterjee 2008 by PHI Learning Private Limited, New Delhi. All rights reserved. No part of this book may be reproduced in any form, by mimeograph or any other means, without permission in writing from the publisher. ISBN The export rights of this book are vested solely with the publisher. Second Printing º º º September, 2008 Published by Asoke K. Ghosh, PHI Learning Private Limited, M-97, Connaught Circus, New Delhi and Printed by Rajkamal Electric Press, B-35/9, G.T. Karnal Road Industrial Area, Delhi

6 To Jamsetji Nusserwanji Tata (3rd March th May 1904) Doyen of the Indian Iron and Steel Industry

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8 Contents Preface Part A GENERAL 1. Introduction 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 Evolution of Ironmaking Technology Since The Developing Blast Furnace Alternative Ironmaking Processes Steelmaking Since Henry Bessemer Bessemer Process Open Hearth Process Electric Furnace Steelmaking Basic Oxygen Steelmaking Secondary Steelmaking and Continuous Casting of Steel Present Status of the World Steel Industry Classification World Production of Steel Steelmaking in India Environmental Pollution and Control Steps Taken by the Steel Industry Forms of Pollution Concluding Remarks 23 References Overview of Blast Furnace Ironmaking Introduction Improvements Made in Blast Furnace Technology Blast Furnace Reactions and Process in a Nutshell 25 vii xix

9 viii Contents 2.3 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 37 References 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 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 Slag 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 78 References 80

10 Contents ix Part B BLAST FURNACE IRONMAKING 5. Physical Chemistry of Blast Furnace Reactions Thermodynamics of the Carbon Oxygen Reaction Combustion of Coke in the Tuyere Zone C CO 2 CO Reaction 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 Kinetics of Reactions in the Stack Kinetics of Reduction of Iron Oxides by CO and H Kinetics of Gasification of Carbon by CO Kinetics of Reduction of FeO by Carbon Direct and Indirect Reduction in the Blast Furnace 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 109 References Thermal and Chemical Features of the Blast Furnace Introduction Mass and Heat Balances Regionwise Heat and Mass Balances Tuyere Flame Temperature RAFT Calculations Tuyere Coal Injection Thermal and Chemical Reserve Zones Concept of an Ideal Blast Furnace Reichardt s Diagram and Thermal Reserve Zone Chemical Reserve Zone 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 Fe X O Gas Equilibrium 124 References Internal Zones and Gas Flow in Blast Furnaces Introduction The Six Internal Zones 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 Gas Flow in Wet Zones Concluding Remarks 136 References 137

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