Learning Center

MANUFACTURING PROCESS
Some of the technological options for converting iron ore to steel products is schematically
shown below.Hot metal and crude steel process are also inter linked among themselves as
represented by arrows.

Basic Flow (PPT file)

Learning Center

SMELTING REDUCTION
TECHNOLOGIES
Smelting reduction usually
produces hot metal from ore in
two steps. Ores are partly
reduced in the first step and
then final reduction and melting
takes place in the second stage.
Some of the most common
process in use are described
below :

COREX
The coal reduction process
(COREX) , was developed by
Voest-Alpine industries (VAI)
and DVAI .This is a two-stage
operation in which DRI from a
shaft furnace like that used in
the Midrex and HYL process is
charged into a final smelter-
gasifier. Reducing gas for the
shaft furnace is produced by
partial combustion of coal with
oxygen in the fluidized bed of
the smelter-gasifier.

The energy needed to complete

the reduction of the DRI and
produce the hot metal and slag
is provided by the partial
combustion. The liquid products
are tapped periodically and
partially spent off gas from the
shaft reducer is exported along
with excess gas produced in the
smelter-gasifier. The smelter-
gasifier operates at 3-5 bars and
comprises an upper fluidized bed
zone at approximately 1500°C
(2730°F) and a lower melting
and liquid collection zone at
approximately 1550°C (2820°F).
Coal and limestone are injected
into the freeboard above the
fluidized bed zone where they
are heated rapidly to 1000-
1200°C (1830-2190°F). The
volatile matter is driven off and
shattered fixed carbon particles
fall into the gasification zone
where a gas with high oxygen
content is injected through blast
furnace-type tuyeres to burn the
carbon to carbon monoxide. The
exothermic combustion provides
the energy to complete the
reduction of the hot DRI and to
melt the slag and hot metal. The
gas leaving the smelter-gasifier
is cooled to 800-900°C (1470-
1650°F) and cleaned in a hot
cyclone to recycle entrained
fines. A portion of the clean gas
is then introduced into the shaft
furnace as reducing gas
containing more than 94% CO
plus H2. The remaining gas is
mixed with the cleaned offgas
from the shaft furnace and the
mixture used as export fuel gas.

COREX uses approximately one

tonne of coal per tonne of hot
metal, with approximately 45%
of the total energy input used in
ironmaking and the rest going to
export fuel gas. The hot metal
produced has carbon and silicon
contents similar to blast furnace
hot metal; however, the sulfur
content is much higher because
nearly all of the sulphur in the
coal enters the slag and hot
metal. In this connection,
organic sulphur in the coal
gasifies and is absorbed by the
DRI and returned to the
smelter-gasifier as iron sulphide.

DIOS
The Direct Iron Smelting
Reduction ( DIOS) was
developed by the Japan Iron and
Steel Federation (JISF) , the
Centre of Coal utilisation and a
consortium of eight Japanese
steelmakers. The DIOS system
has three fluidised
furnaces .Iron ore is preheated
in the first of two fluidized bed
reactors in series and pre-
reduced to 15-25% in the
second reactor using cleaned
offgas from the smelter. Dust
removed from the smelter, off-
gas and fines removed from the
gases leaving the fluidized bed
reactors are injected back into
the smelter. In addition, a small
amount of coal fines, of the
order of 50 kg per tonne of hot
metal production, is injected into
the smelter offgas to cool the
offgas and provide additional CO
and H2 for pre-reduction. Most
of the coal, 600-700 kg per
tonne of hot metal, is gravity-
fed into the smelter. Oxygen is
injected into the smelter for
combustion of primary coal and
for post-combustion. The oxygen
lance is designed to provide both
high velocity oxygen for carbon
oxidation (hard blow) and lower
velocity oxygen for post-
combustion in the freeboard
(soft blow) simultaneously. The
aim post-combustion is
approximately 40%, and with
pre-reduction to 20%, the coal
consumption is roughly 700-800
kg per tonne of hot metal
depending on coal type.

AUSMELT
The Ausmelt process was
developed by Ausmelt Ltd.
Australia . Lump ore or ore fines
are fed continuously into a
converter along with lump coal
and flux. Fine coal , oxygen and
air are injected through a top
lnce to allow submerged
combustion. The degree of
oxidation and reduction is
controlled by adjusting fuel to
air and coal ratios as well as the
proportion of fine coal injected
down the lance. All reactions are
completed in a single reactor.

HISMELT
The Hismelt process was
developed by CRA ltd., Australia
and Midrex Corporation , United
States .Coal is injected through
bottom tuyers into a molten
bath. Carbon is rapidly dissolved
and reacts with oxygen from
incoming iron ore to from carbon
monoxide and iron. This reaction
is endothermic and therefore to
keep the process going
additional heat has to be
supplied .This is achieved by
reacting carbon monoxide
released from the bath with
oxygen from top injection of air.
Reacted hot gasses exit the
vessel and are used in a
fluidised bed to pre- heat and
pre-reduce incoming ore.

ROMELT
The ROMELT process was
developed by Moscow institute
of steel and alloys in Russia . A
major feature is there is no pre-
reduction process step. The
smelter has a water-cooled roof
and sidewalls in contact with
slag and conventional
refractories in contact with the
metal. A mixture of air and
oxygen is injected through two
rows of tuyeres. Coal and ore
are fed by gravity. The system,
simple and robust. ROMELT
consumes more energy than
other smelting processes due to
the lack of pre-reduction and
extensive water cooling.

Plasmasmelt
In plasma-based smelting
reduction processes, the
reactions take place in a coke-
filled shaft furnace with tuyeres
 spaced symmetrically around
the lower part of the furnace.
The shaft is completely filled
with coke.Plasma generators
and equipment for injection of
metal oxides mixed with slag
forming material and possibly
reductants are attached to the
tuyeres. In front of each tuyere
a cavity is formed inside the
coke column where reduction
and smelting take place. At
regular intervals the produced
slag and metal are tapped from
the bottom of the shaft furnace.
In the case of iron ore smelting
the off-gas from the furnace,
consisting mainly of carbon
monoxide and hydrogen, can be
used for pre reduction of the
ore.In other applications of the
process, such as reclaiming of
alloying metals from baghouse
dust, the produced gas is
utilised as a fuel gas.If the raw
material contains metals with
high vapour pressures, for
example zinc and lead, these
metals leave the furnace with
the off-gas which is then passed
through a condensor where the
metals are recovered from the
gas.
IMPORTANCE OF STEEL
Steel has had a major influence on our lives, the cars we drive, the
buildings we work in, the homes in which we live and countless other
facets in between. Steel is used in our electricity-power-line towers,
natural-gas pipelines, machine tools, military weapons-the list is
endless. Steel has also earned a place in our homes in protecting our
families, making our lives convenient, its benefits are undoubtedly
clear.

Steel is by far the most important, multi-functional and most adaptable

of materials. The development of mankind would have been impossible
but for steel. The backbone of developed economies was laid on the
strength and inherent uses of steel.

The various uses of steel which in turn is a measure of adaptability of

steel can be judged from the following characteristics of steel :
- Hot and cold formable
- Weldable
- Suitable machinability
- Hard, tough and wear resistant
- Corrosion resistant
- Heat resistant and resistance to deformation at high temperatures.
Steel compared to other materials of its type has low production costs.
The energy required for extracting iron from ore is about 25 % of what
is needed for extracting aluminum. Steel is environment friendly as it
can be recycled. 5.6 % of element iron is present in earth's crust,
representing a secure raw material base . Steel production is 20 times
higher as compared to production of all non-ferrous metals put together.

The steel industry has developed new technologies and has strived hard
to make the world's strongest and most versatile material even better.
There are altogether about 2000 grades of steel developed of which
1500 grades are high grade steels. There is still immense potential for
developing new grades of steel with varying properties .The large
number of grades gives steel the characteristic of a basic production
material Steel has enjoyed an important position in our lives and will
continue to do so in the years to come. However, the degree to which it
maintains its dominant position will depend on if steel can exploit its
potential by developing new higher grades and adaptable grades . This
can be achieved by refining the structure and applying alloying
techniques and thus furthering its utility value. We will have to find out
ways to use steel and be ready to face a stiff competition from
Aluminium in the future.

DIRECT REDUCTION TECHNOLOGIES

Direct reduction processes are of significance and can form an alternative to a conventional
Blast furnace. Solid sponge iron ( direct reduced iron or DRI) is produced by removing oxygen
from the ore .The technique of Direct reduction varies according to the type of reducing agents
employed and the metallurgical vessel in which they are reduced. The reducing agents used
normally are :

 Gas reduction
 Solid reducing agents

Gas reduction is more commonly used . Depending on the reduction vessel employed ,
there are:
 Shaft furnaces
 Rotary kiln furnace
  Fluidised bed and
 Retort process.

Reducing gasses are carbon monoxide , hydrogen and their mixture which are generally found
in natural gasses. The directly used solid reducing agents are coals of any size, so that there is
no need for expensive coke. The continuous shaft furnace which uses reducing gasses is more
common. Midrex, HYL III process are of this type. HYL I process is of discontinous retort type.
SL/RN and Krupp-Codir are of rotary kiln type . These processes use solid reducing agents and
operate in continuous flow. Ores for direct reduction have to meet stringent specifications with
high percentage of Fe and low content of tramp elements. Pellets are used mainly for this
purpose. The output of all DRI processes is Sponge Iron Sponge iron is also hot briquetted to
HBI .DRI combined with an EAF is considered as an efficient steel making technique.