Modern iron making handbook

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Bibliographic Details
Main Author Tupkary, R. H. (Author)
Format Electronic eBook
LanguageEnglish
Published Dulles, Virginia : Mercury Learning & Information, [2018]
SeriesMLI handbook series.
Subjects
Iron > Metallurgy.
elektronické knihy
electronic books
Online AccessFull text
ISBN9781523114467
1523114460
9781683921363
1683921364
Physical Description1 online resource (xvii, 492 pages)

Cover

Table of Contents:
  • Machine generated contents note: 1.1. Ancient Ironmaking
  • 1.2. Historical Ironmaking Processes
  • 1.3. Developments that Led to Modern Ironmaking
  • Coke Furnace
  • Hot Blast Generation
  • Blast Furnace Gas Cleaning
  • Charging Devices
  • Pig Casting Machine
  • 1.4. Modern Ironmaking
  • 1.5. Alternative Methods of Iron Production
  • 1.6. History of the Iron and Steel Industry in the United States
  • 1.7. Twenty-first Century Trends (U.S. and the World)
  • U.S. Production of Selected Mineral Commodities in the First Quarter 2017
  • 1.8. Concluding Remarks
  • 2.1. Introduction
  • 2.2. Modern Blast Furnace
  • Furnace Details
  • 2.3. Hot Blast Stove
  • 2.4. Gas Cleaning
  • 2.5. Raw Materials Storage and Handling
  • 2.6. Liquid Products Disposal
  • Hot Metal Ladles
  • 2.7. Blast Furnace Operation and Control
  • 2.8. Essentials of the Blast Furnace Process
  • Stack or Shaft
  • Bosh
  • Tuyere or Combustion Zone
  • Hearth
  • 2.9. Efficiency of Blast Furnace
  • 2.10. Concluding Remarks
  • Note continued: 3.1. Introduction
  • 3.2. Iron Ores
  • World Deposits of Iron Ores
  • 3.3. Metallurgical Coal
  • Metallurgical Coal Reserves
  • 3.4. Limestone and Dolomite as Flux
  • 3.5. Concluding Remarks
  • 4.1. Introduction
  • 4.2. Functions of Coke
  • 4.3. Quality Requirements of Coke
  • Reactivity
  • Size
  • Strength and Abrasion Resistance
  • Micum Test
  • ASTM Tumbler Test (U.S.)
  • Preparation of BF Fuel
  • 4.4. Preparation of Coke (India)
  • Coal Ranking (U.S.)
  • 4.5. Modifications in Coke Making Practices
  • Stamp Charging of Coke Ovens
  • Economizing Coke-Charge-Mix
  • Use of Waste Plastic in Coke Making
  • 4.6. Alternative Fuels
  • 4.6. Ferro-coke
  • 4.7. Concluding Remarks
  • 5.1. Introduction
  • 5.2. Elements of Distribution
  • 5.3. Factors Affecting Distribution
  • Factors Affecting Distribution Inside the Furnace
  • Angle and Size of the Big Bell
  • Angle of Repose and Shape of Particles
  • Order of Charging
  • 5.4. Limitations
  • 5.5. Concluding Remarks
  • Note continued: 6.1. Introduction
  • Lumps
  • Coarse Fines
  • Very Fine Fines
  • 6.2. Burden Qualities
  • Physical
  • Chemical
  • 6.3. Crushing and Sizing
  • 6.4. Beneficiation of the Iron Ores
  • Magnetic Concentration
  • Gravity Methods
  • Flotation Method
  • Electrostatic Separation
  • Magnetic Roasting
  • Washing
  • Drying
  • 6.6. Calcining/Roasting
  • 6.7. Blending
  • 6.8. Shipping
  • 6.9. Products of Ore Processing
  • 6.10. Treatment of Iron Ores (India)
  • Ore Treatment at Tata Steel
  • Alumina Problem and Beneficiation
  • Treatment of Goa Ores
  • Kundremukh Iron Ore Project
  • 6.11. Agglomeration of Iron Ores
  • Briquetting
  • Nodulizing
  • Vacuum Extrusion
  • Sintering
  • Pelletizing
  • 6.12. World Resources (2017 USGS)
  • Substitutes
  • 6.13. Concluding Remarks
  • 7.1. Principle of Sintering
  • 7.2. Process Variables
  • 7.3. Sinter Quality
  • 7.4. Mechanism of Sintering
  • 7.5. Raw Material Requirements
  • Size
  • Fuel Content
  • Moisture
  • Circulating Load
  • Note continued: Performance of Sintering Machine
  • Economics
  • 7.6. Recent Trends in Sintering Practice
  • 7.7. Alumina Problem in Sintering
  • Indian Scenario
  • 7.8. Concluding Remarks
  • 8.1. Introduction
  • 8.2. The Pelletization Process
  • 8.3. Theory of Bonding
  • 8.4. Mechanism of Ball Formation
  • Nucleii Growth Region
  • Transition Period
  • Ball Growth Region
  • Growth by Assimilation
  • Growth by Layering
  • 8.5. Feed Size, Shape, and Porosity
  • 8.6. Green Ball Production
  • Disc Pelletizer
  • Drum Pelletizer
  • 8.7. Additives
  • 8.8. Induration of Pellets
  • Drying
  • Preheating and Firing
  • Firing Units
  • 8.9.Comparison of the Pellet Firing Machines
  • 8.10. Indian Pelletization Plants
  • 8.11.U.S. Production (Pelletization)
  • 8.12. Concluding Remarks
  • 9.1. Introduction
  • 9.2. Room Temperature Physical Properties
  • Shatter Tests
  • Tumbling and Abrasion Test
  • Compression Test
  • Porosity
  • 9.3. Reducibility
  • Note continued: 9.4. Physical Behavior of Materials During Reduction at High Temperatures
  • Decrepitation
  • Low-Temperature Breakdown Test (L.T.B.T.)
  • Reduction Degradation Index Test (R.D.I)
  • Reducibility Test (R.I.) on Iron Bearing Materials
  • Coke Reactivity Test (C.R.I.) and Coke Strength after Reaction (C.S.R.)
  • Hot Compression Strength
  • Swelling
  • Softening of Materials in the Blast Furnace
  • High Temperature Permeability Under Reducing Conditions and Applied Load
  • 9.5. Concluding Remarks
  • 10.1. Introduction
  • 10.2. The Blast Furnace Profiles
  • Thermal, Physical, and Chemical Profiles
  • Physical Structure
  • 10.3. Thermodynamic Equilibria
  • Carbon-Oxygen Equilibria
  • Equilibria in Fe-C-O and Fe-O-H Systems
  • Elements of Stoichiometry
  • 10.4. Physical Chemistry of Blast Furnace Process
  • Reactions in the Tuyere Zone
  • Reactions in Stack
  • Kinetics of Iron Oxide Reduction
  • Physical Nature of Ore and Its Previous History
  • Note continued: Nature and Composition of Gangue in the Charge
  • Temperature and Carbon Monoxide Content of Gases
  • Chemical Nature of Iron Oxide
  • Pressure
  • Solid-Solid Reaction
  • Reactions in the Bosh
  • Reactions in the Hearth
  • Sulphur Reaction
  • 10.5. Alumina Problem
  • Indian Ores
  • 10.6. Kinetics of Reactions in Bosh and Hearth
  • 10.7. Efficiency of the Blast Furnace Process
  • Elements of Enthalpy Balance
  • Process Zones in a Blast Furnace
  • Thermal Efficiency
  • 10.8. Quality of Hot Metal
  • Silicon Content of Hot Metal
  • 10.9. TiO2 Addition in Burden
  • 10.10.U.S. and World Events, Trends, and Issues. Source: USGS 2017
  • Recycling
  • Import Sources (2012-15)
  • Trends and Issues
  • World Mine Production and Reserves
  • 10.11. Concluding Remarks
  • 11.1. Blast Furnace Refractories
  • Stack Lining
  • Hearth Lining
  • Hearth Walls
  • Bosh Lining
  • Carbon-lined Furnaces
  • 11.2. Blast Furnace Structure
  • 11.3. Blast Furnace Cooling Arrangements
  • Note continued: Shaft Coolers
  • Hearth and Bosh Coolers
  • Cooling of Hearth Bottom
  • 11.4. Tap Holes
  • 11.5. Cast House
  • 11.6. Tuyere Assembly
  • 11.7. Raw Material Section
  • 11.8. Charge Hoisting Appliances
  • 11.9. Top Charging System
  • 11.10. Blowers, Boilers, Pumps, etc
  • 11.11. Slag-granulation
  • 11.12. Instrumentation and Control
  • 11.13. Concluding Remarks
  • 12.1. Uptake, Downcomer, and Bleeder
  • 12.2. Dust Catcher
  • 12.3. Semi-Fine or Primary Cleaning
  • Scrubbers or Spray Towers
  • Venturi Washer
  • 12.4. Fine or Secondary Cleaning
  • Electrostatic Precipitator (ESP)
  • 12.5. Utilization of Blast Furnace Gas
  • 12.6. Hot Blast Stove
  • Construction of the Stove and Its Accessories
  • 12.7. Concluding Remarks
  • 13.1. Blowing-in
  • Drying
  • Filling
  • Lighting and Operating Until Routine Practice is Established
  • 13.2. Banking
  • 13.3. Blowing-out
  • 13.4. Tapping
  • 13.5. Fanning
  • 13.6. Back Drafting
  • 13.7. Conclusions
  • 14.1. Hanging
  • Remedies
  • Note continued: 14.2. Scaffolding
  • 14.3. Slip
  • 14.4. Chilled Hearth
  • 14.5. Pillaring
  • 14.6. Breakout
  • 14.7. Choking of Gas Offtake
  • 14.8. Flooding and Coke Ejection Through the Tap Hole
  • 14.9. Leaking Tuyeres, Tap Holes, and Coolers
  • 14.10. Channeling
  • 14.11. Salamander Formation
  • 14.12. Concluding Remarks
  • 15.1. Introduction
  • 15.2.Composition of Pig Iron
  • 15.3. Slag Composition
  • Slag Volume
  • How to Calculate the Slag Volume?
  • Disposal of Slag
  • 15.4. Production of Ferro-Manganese
  • 15.5. The Sulfur Problem
  • 15.6. Basic Burdening of Blast Furnace and External Desiliconization
  • 15.7. Acid Burdening of Blast Furnace and External De sulfurization
  • Indian Practice of Acid Burdening
  • 15.8. Disposal of Metal
  • 15.9. Concluding Remarks
  • 16.1. Introduction
  • 16.2. Burden Distribution
  • 16.3. Burden Trajectory and Profiles
  • 16.4. Burden Distribution Patterns
  • 16.5. Blast Furnace Performance
  • 16.6. Effect of Sizing
  • Note continued: 16.7. Use of Agglomerate as Burden
  • Sinter
  • Pellets
  • 16.8. Sinter vs. Pellets
  • 16.9. Agglomerate vs. Natural Lumpy Ore
  • 16.10. Sizing of Coke and Its Quality
  • 16.11. Flux Quality
  • 16.12. Concluding Remarks
  • 17.1. Introduction
  • 17.2. Large-Capacity Blast Furnaces
  • 17.3. Coke Quality
  • 17.4. Burden Preparation
  • 17.5. Improved Distribution of Charge
  • Stock-line Armor
  • 17.6. High Top Pressure
  • 17.7. Charging Devices for High Top Pressure
  • Tops with Only Bells
  • Paul-Wurth/CRM Top
  • NKK's Four Bell Top
  • Tops with Bells and Valve Seals
  • Bell Construction and Operation
  • Top with Only Valve Seals (No Bells)
  • Gimble Top Distributor
  • 17.8. Higher Blast Temperature and Driving Rate
  • 17.9. Oxygen Enrichment of Blast
  • 17.10. Humidification of Blast
  • 17.11. Fuel Injection
  • Pulverized Coal Injection
  • 17.12. Lime Injection
  • 17.13. Pre-reduced Ore as Burden
  • 17.14. Injection of Reducing Gas at the Bottom of the Stack
  • Note continued: 17.15. Utilization of Plant Iron-Bearing Wastes
  • 17.16. Concluding Remarks
  • 18.1. Introduction
  • 18.2. Process Variables
  • Variety of Operational Variables
  • 18.3. Probes for Measuring the Process Variables
  • 18.4. BF Operational Models
  • 18.5. Process Control Strategies
  • Overall Control Strategy
  • 18.6. Central Working Index
  • 18.7. Advantages of Process Control
  • 18.8. Concluding Remarks
  • 19.1. Introduction
  • 19.2. The Low-Shaft Furnace
  • 19.3. Mini-Blast Furnaces (MBFs)
  • Special Features of MBF
  • Modern MBFs
  • Chinese MBF
  • First MBF in India
  • Charcoal Blast Furnace
  • 19.4. Concluding Remarks
  • 20.1. General
  • 20.2. Historical
  • India
  • 20.3. The Submerged Arc Furnace Plant
  • 20.4. Operation
  • 20.5. Smelting Practice
  • 20.6. Modern Trends
  • 20.7. Special Features
  • 20.8. Irregularities in Operations
  • 20.9. Concluding Remarks
  • 21.1. Introduction
  • 21.2. Physical Chemistry of DR Processes
  • 21.3. Sponge Ironmaking Processes
  • Note continued: HyL Process
  • 21.4. Midrex Process
  • Other Gaseous Reduction Processes
  • Gas-based Processes
  • 21.5. Fluidized Bed Processes
  • 21.6. Coal-Based DR Processes
  • General Design Features
  • Raw Materials
  • Product
  • Ring Formation in a Rotary Kiln
  • Coal-based Process Designs
  • Process Control
  • 21.7. Coal-Based Shaft Furnaces
  • 21.8. Gasified Coal-Based Processes
  • 21.9. Sponge Iron Production in India
  • 21.10. Metallurgical Properties of Sponge Iron
  • 21.11. Use of Sponge Iron
  • 21.12. Concluding Remarks
  • 22.1. Introduction
  • 22.2. Classification of SR Processes
  • 22.3. Thermo-chemical Model
  • 22.4. Vertical Shaft Furnace Processes
  • Corex Process
  • Sumitomo SC Process
  • Kawasaki Process (SR)
  • Finex Process
  • Technored Process
  • 22.5. Electrical Processes
  • INRED Process
  • ELRED Process
  • COMBISMELT Process
  • Plasmasmelt Process
  • Fastmelt Process
  • 22.6. Converter Processes
  • Krupp-COIN Process
  • PCIG Process
  • HI-Smelt Process
  • Note continued: Reactor Steelmaking Process
  • AISI-HyL Direct Steelmaking
  • 22.7. Bath Smelting Processes
  • Romelt (Earlier FLPR) Process
  • DIOS (Direct Iron Ore Smelting Process)
  • 22.8. Rotary Hearth Furnace Processes (RHF)
  • IT mk3 Process
  • 22.9. TUPKARY-SR Process
  • 22.10. Concluding Remarks.

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