Pig iron manufacturing process pdf

The specialty of openhearth furnaces is the extreme heat that can be obtained from them due to their regenerative process. Metal foundries produce molten iron by melting scrap iron, pig iron, and scrap steel in a traditional cokefired cupola furnace, or in electricinduction or electricarc furnaces. Pig iron is an unrefined product that has been converted from iron ore, one step in the process to create steel. Methods for manufacturing steel have evolved significantly since industrial production began in the late 19th century. Pig iron is the product of smelting iron ore also ilmenite with a highcarbon fuel and reductant such as coke, usually. Substances and are used in the melting process of the iron casting industry. Pig iron blast furnace route international iron metallics association. Charcoal and anthracite are also used as fuel and reductant. The basic materials used for the manufacture of pig iron are iron ore, coke, and limestone. Cast iron is made from pig iron, which is the product of melting iron ore in a blast furnace. In the bof process, coke making and iron making precede steel making. Only a limited portion of the pig iron produced with such effort this fall will be made into steel.

The process duration varies with the injection rate, hot metal chemistry, and desired final sulfur content, and is in the range of 5 to 30 minutes. It constitutes 5 percent by weight of the earths crust, and it is the. However, voest and oamg commercialized this method in 195253. In the conventional integrated steel manufacturing process, the iron from the blast furnace is converted to steel in a basic oxygen furnace. Treatment in molten state of ferrous alloys refining metals in general c22b 900 warning in this subclass nonlimiting references in the sense of paragraph 39 of the guide to the ipc may still be displayed in the scheme. Have any question, please enter the form below and click the submit button. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned.

The modern steel manufacturing process the balance. Pdf the production of pig iron from crushing plant waste using hot. Laboratory study related to the production and properties of pig iron. The alloy constituents affect its colour when fractured. It is the process of making steel from carbonrich molten pig iron.

The blast furnace uses coke, iron ore and limestone to produce pig iron. In these processes, pig iron is melted and a strong current of air is directed over it while it is stirred or agitated. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work. Commercially available iron is classified based on purity and the abundance of additives. The cupola furnace works on the principle where we generate heat from burning coke and when the temperature of the furnace is above the melting point of the metal then the metal is melt the charge introduced in the cupola consists of pig iron, scrap, casting rejection, coke, and flux. Contaminants are removed from the melted pig iron, and the iron, once melted, is then cast. Iron manufacturing process pig iron cast iron and wrought iron genuine chemistry the ultimate resource for chemistry. Pig iron is the product of smelting iron ore also ilmenite with a highcarbon fuel and reductant such as coke, usually with limestone as a flux. The name pig iron comes from the resemblance of the long channel to a mother pig, and the smaller channels to suckling piglets.

H, or enthalpy, determines the energy cost of the process. Pig iron has only limited uses, and most of this iron goes on to a steel mill where it is converted into. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. Its usefulness derives from its relatively low melting temperature.

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. The process was introduced and developed in 1948 by robert durrer. This reduction process is carried out in a furnace called blast furnace. The raw materials used include ore, sinter, coke, lime and various aggregates. Feb 12, 2018 pig iron is produced in blast furnace by reducing iron ore with carbon monoxide indirect reduction and carbon direct reduction. List of class i designated chemical substances related to melting process no.

Iron and steel manufacturing international finance corporation. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron. In most modern pig iron production, however, this process is no longer used, as methods have been developed that allow the pig iron to be transported in a liquid state, rather than as a hard material. Metal casting is an energy and materials intensive manufacturing process, which is. An iron producer operating a blast furnace uses this iron ore as a raw material and smelts it into a product, pig iron, in a blast furnace. Our foundry pig iron are used widely for a various fields of castings in the manufacturing industry. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work was conducted in it. The manufacture of iron is based on the principle of reduction of iron oxide with carbon monoxide. Cast iron is then derived from pig iron that has been remelted, along with scrap iron and scrap steel.

Modern blast furnaces produce more than 10,000 tonnes per day. Plants that use electric arc furnaces can be sited closer to the market. The process is named after its inventor, henry bessemer, who took out a patent on the process in 1855. The cupola furnace works on the principle where we generate heat from burning coke and when the temperature of the furnace is above the melting point of the metal then the metal is melt. Directreduced iron has about the same iron content as pig iron, typically 9094% total iron depending on the quality of the raw ore so it is an excellent feedstock for the electric furnaces used by mini mills, allowing them to use lower grades of scrap for the rest of the charge or to produce higher grades of steel. Raw materials in blast furnace are iron ore, metallurgical coke and suitable fluxes like dolomite, lime etc.

Pig iron is produced by smelting or iron ore in blast furnaces or by smelting ilmenite in electric furnaces. The second is to make wrought iron or steel from pig iron by puddling process a further process. Pig iron is the product of smelting iron ore also ilmenite with a. Pig iron is a fe based alloy generally having a carbon content of 45 percent, containing other elements too and produced by a metallurgical process from iron ores. A method of operating a blast furnace in which the blast furnace gas is stripped of nitrogen by the use of a molecular sieve and recycled. Pig iron blast furnace route international iron metallics. A blast furnace for converting iron oxides to iron metal. Pig iron has a very high carbon content, typically 3. Where market size permits, some degree of product specialisation is practised. Even though equipment is improved and higher production rates can be achieved, the processes inside the blast furnace remain the same. Apr 27, 2015 4272015 7 production of pig iron process 1.

Metallurgical coke is required for the production of pig iron and for use in a. The chapters 4 through 7 highlight various aspects of. Other sources of slag include the copper, lead, and phosphate industries. The bessemer process was the first inexpensive industrial process for the massproduction of steel from molten pig iron. The production process has 3 primary componentsmolten mineral generation in the cupola, fiber formation and collection, and final product formation. The pig iron is obtained from the iron ores in the following steps. The carbon escapes mainly as carbon monoxide, while the oxidised silicon, sulphur4 and phosphorus segregate into the slag. Pdf a production of pig iron has been conducted from crushing plant waste. It is the molten iron from the blast furnace, which is a large and cylindershaped furnace charged with iron ore, coke, and limestone. Pig iron and refined iron ore pellets briquetted iron can also be used, and because this. Molten iron is refined by adding alloying metals into either the furnace or a ladle.

For general information about merchant pig iron, please visit the pig iron page. Apr 01, 2020 the name pig iron comes from the resemblance of the long channel to a mother pig, and the smaller channels to suckling piglets. Oxygen blowing converts the pig iron to steel by oxidation of the carbon, silicon, and phosphorus. Iron manufacturing process pig iron cast iron and wrought. Cast iron can be made directly from the molten pig iron or by remelting pig iron, often along with substantial quantities of iron, steel, limestone, carbon coke and taking various steps to remove undesirable contaminants. The iron ore concentrate is now mixed and ready for the pelletizing process.

Raw materials procurement coal pallets lump ore fuel oil limestone alloying medium engineering materals ii meng 2122 8. Limestone is crushed, sized, dried and stored in storage silos. Convert the following flow chart into a paragraph of about 150 words. The charge introduced in the cupola consists of pig iron, scrap, casting rejection, coke, and flux. It is produced by reduction of iron oxides, in the liquid state, in blast furnaces. But process already beginning of amalgamating the more efficient local pig iron producers and eliminating the less efficient ones in any case many will be ruined by winter frosts, c. Blast furnaces are used to produce pig iron from iron ore for subsequent. Pig iron is the intermediate product of smelting iron ore with a highcarbon fuel such as coke, usually with limestone as a flux. Ferromanganese, silicomanganese manufacture for alloying steel.

Steel production american iron and steel institute. If all the carbon is removed from the iron to give high purity iron, it is known as wrought iron. The process of making cement is described in this flow chart. Iron ore is converted into various types of iron through several processes. This section deals with the types of iron and steel which are produced as a result of the steelmaking process. What is the method of production of pig iron by using a blast. Jan 14, 2020 methods for manufacturing steel have evolved significantly since industrial production began in the late 19th century. The process of preparing pig iron was using hot blast cupola. Since pyrite contains only 30 to 40% iron, therefore it is not used for manufacturing pig iron. The blast furnace is a countercurrent gassolids reactor in which the descending column of burden materials coke, iron ore and fluxesadditives reacts with the ascending hot gases. These reactions involve numerous different solids, liquids, and gases, and are carried out using many diverse types of furnaces. Iron fe is a relatively dense metal with a silvery white appearance and distinctive.

A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Class i designated chemical substance content % 1 pig iron 311 manganese mn 0. Modern methods, however, are still based on the same premise as the original bessemer process, which uses oxygen to lower the carbon content in iron. To ensure that the production process maintains a high and stable level of quality, these materials have to be metered precisely and supplied to the blast furnace in batches. Primary metal production pyrometallurgy deals with chemical reactions at high temperatures ranging from 100c up to 3000c.

Sep 18, 2019 cast iron has already been mentioned above. Pig iron is an intermediate product of the iron industry, also known as crude iron, which is. Pdf pig iron nuggets were produced in a laboratoryscale furnace at michigan technological university. Wrought iron is quite soft and easily worked and has little structural strength. Dec, 2018 the manufacture of iron is based on the principle of reduction of iron oxide with carbon monoxide. Cast iron is a group of iron carbon alloys with a carbon content greater than 2%. Further, solid pig iron is used as pure raw material and carbon source in eafs. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. The two raw materials used in theprocess are limestone and clay.

What is the method of production of pig iron by using a. The process is continuous with raw materials being regularly charged to the top of the furnace and. The blast furnacebof route produces almost 66% total crude steel, and eaf route accounts for about 31%, while the blast furnace open hearth process, which dominated steelmaking in the first half of the 1900s, had only a share of about 3% left 7. The charge of pig iron, steel scrap, iron ore, and flux are together kept in a shallow container with a flame burning above it. This pig iron is either solidified for later remelting in engineering foundries or else kept molten and passed on to steelworks. Originally, the iron was collected in pools called pigs, which is the origin of the name pig iron. Dec 29, 2012 pig iron is the intermediate product of smelting iron ore with a highcarbon fuel such as coke, usually with limestone as a flux. Cast iron begins its life as pig iron, which is remelted and often combined with large amounts of scrap iron and sometimes with steel. The industrial ecology of the iron casting industry core.

The name ld converter came after the name of the two austrian towns linz and donawitz. The bessemer process wirral model engineering society. Pig iron and cast iron are different types of metal. Pig iron is produced in blast furnace by reducing iron ore with carbon monoxide indirect reduction and carbon direct reduction. General principles of production of metals by pyrometallurgy. Pig iron and its manufacturing mechanical engineering. How iron is made material, manufacture, making, history. It is the process of removing the impurities like clay, sand etc. The first blast furnaces appeared in the 14th century and produced one ton per day. In addition, pig iron contains some sulphur and phosphorus. Charcoal and anthracite have also been used as fuel. The output product from the blast furnace thus becomes the main raw material. The haematite is widely used for the production of pig iron. In the operation of a blast furnace in which iron ore is reduced by the combustion of coke and hot air to produce iron and blast furnace gas and in which the hot air is admitted to the blast furnace continuously, the improvement comprising withdrawing the blast furnace gas resulting from the reduction process from the blast furnace, stripping nitrogen from at.

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. Pig iron is usually used in the manufacturing of ingot and billet. The most common process is the use of a blast furnace to produce pig iron which is about 9294% iron and 35% carbon with smaller amounts of other elements. Iron and steel manufacturing industry description and practices steel is manufactured by the chemical reduction of iron ore, using an integrated steel manufacturing process or a direct reduction process. Pig iron is an intermediate product of the iron industry, also known as crude iron, which is obtained by smelting iron ore in a blast furnace. Coke is the fuel and limestone are added as a flux to. Phosphorus and sulfur may be burnt out of the molten. H is negative, then heat is given off by the reaction, and the process will be.

It is then moved to a pouring station for pouring into molds. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Structural analysis of sinter with titanium additionanaliza. Pig iron pig iron is an alloy of iron with carbon about 4. Open hearth process an overview sciencedirect topics. Pig iron and refined iron ore pellets briquetted iron can also be used, and because his t method is economic at lower volumes these operations are called mini mills. Jun 28, 2015 the haematite is widely used for the production of pig iron.