Steel plant ppt 1

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2. Notes
Strategic location –
Vizag, Andhrapradesh
Established : 1982
5
th
Rank in the World
Capacity of -252,000 Tons
Per year

3. World Steel Industry –Top Ten
S. Korea
53.6 mT
6
Italy
30.6 mT
10
8
Ukraine
38.6 mTGermany
45.8 mT
7
3
USA
91.4 mT
4
Russia
68.5 mT
9
Brazil
33.7 mT
5
Global crude steel Production: 1326.5million tonnes(Mt)
1
China
502 mT
2
Japan
118.7 mT

4. STEEL MANUFACTURING

5. WHATISSTEEL?
In the beginning, there was iron...
Then came cast iron...
...and finally steel

6. GENERALISSUESABOUTSTEEL
•Steel has been called the world’s most
useful and inexpensive metal.
•In recent decades ,steel manufactures
have been forced to take a much closer
look at what their processes have been
doing to the fragile environment around
them.

7. WHATISSTEELUSEDFOR-I
The structures such as oil
platforms, catalytic converters,
paper clips, mounts for electronic
chips...are all made of steel.
1.In the construction of
bridges or buildings...
2. In the automobile sectorfor
the manufacture of
automobile parts

8. WHATISSTEELUSEDFOR-II
3. For everyday uses:
cans,pots,containers,etc...
4. At the heart of food
preservation...
5. In communications...6. In energy... 7. In health...

9. STEELPRODUCTS
Semi-finished products(continuous cast steel)
Finished products (rolled steel)

10. STEELMANUFACTURINGPROCESS
INFRASTRUCTURE
Coke Ovens And Coal Chemical Plant
Sinter Plant
Blast Furnace
Steel Melt Shop And Continuous Casting
LMMM
WRM
MMSM

11. CONVERSIONOFCOALINTOCOKE
It Can Be Achieved By Using Coke Ovens And Coal Chemical Plant
Heating the blended coal charge in absence of air at a temperature of
1000
o
C-1050
o
C for a period of 16/19 hours.
Coke ovens

12. The volatile matter of coal liberated during carbonization is collected
in gas collecting mains and cooled with ammonia liquor spray.
The gas cooled from 800
o
C to 80
o
C is drawn to Coal Chemical Plant
by Exhauster.
The residual coke is pushed out of the oven by pusher car through a
guide into coke bucket.
The red-hot coke is taken to coke dry cooling plant for cooling.

13. Ammonium Sulphate(NH4)2SO4
Crude Tar,
Crude Benzol and
Cleaned coke oven gas.
Cooled Coke from CDCP (Coke Dry Cooling Plant) is separated i
into 3 Fractions
BF Coke i.e. +25-70mm which is sent to Blast Furnaces
Coke Breeze i.e. +0-15mm which is sent to Sinter making and
Nut coke i.e., +15-25mm, which is also used in the Blast furnace.
Different Cokes Obtained
BYPRODUCTS

15. HOWISSTEELMADE-I

16. STEELMAKINGPLANT
Electric Arc Furnace Ladle Furnace Continuous Casting Machine

18. What is a Blast Furnace?
•Blast furnace is used to
reduce and convert iron
oxides(ore) into liquid iron
called "hot metal".
•The blast furnace is a
huge, steel stack lined
with refractory brick.
•Iron ore, coke and
limestone are put into the
top, and preheated air is
blown into the bottom.

19. Why does Iron have to be extracted
in a Blast Furnace???
•Iron have to be extracted in the blast furnace
because it can be displaced by carbon.
•This is more efficient method than electrolysis
because it is more cost effective

22. Three substances are needed to enable to extraction of iron
from its ore. The combined mixture is called the CHARGE.
Iron ore, haematite-often contains sand with iron oxide,
Fe
2
O
3
Limestone(calcium carbonate).
Coke-mainly carbon
The charge is placed a giant chimney called aBLAST
FURNACE.The blast furnace is around 30 metres high and
lined with fireproof bricks. Hot air is blasted through the
bottom.
The Method

24. •Oxygen in the air reacts with coke to give
carbon dioxide:
C
(s)
+ O
2(g)
CO
2(g)
•The limestone breaks down to form carbon
dioxide:
CaCO
3(s)
CO
2(g)
+ CaO
(s)
•Carbon dioxide produced in 1 + 2 react with
more coke to produce carbon monoxide:
CO
2(g)
+ C
(s)
2CO
(g)
Reactions that take place in a BLAST FURNACE

25. •The carbon monoxide reduces the iron in the ore
to give molten iron:
3CO
(g)
+ Fe
2
O
3(s)
2Fe
(l)
+ 3CO
2(g)
•The limestone from 2, reacts with the sand to
form slag (calcium silicate):
CaO
(s)
+ SiO
(s)
CaSiO
3(l)

26. •Both the slag and iron are drained from the bottom of
the furnace.
•The slag is mainly used to build roads.
•The iron whilst molten is poured into moulds and left to
solidify -this is called cast iron and is used to make
railings and storage tanks.
•The rest of the iron is used to make steel.

27. •Steel is made in steel melting shop in the
refractory lined vessels called LD
Converters by blowing oxygen through the
hot metal bath.
•Steel making is an oxidation process in
which oxygen reacts with the carbon in the
hot metal and releases large quantities of
gas rich in carbon monoxide along with
huge amount of dust.
Steel Making Shop (SMS)

28. •Hot Metal, Steel Scrap and Fluxes such as calcined lime or Dolomite
are added as charge to the Convertors.
•The gases released from the converter are collected, cooled, cleaned
and recovered for use as fuel in the steel plant.
•The entire molten steel is continuously cast at the radial type
continuous casting machines resulting in significant energy
conservation and better quality steel.

30. Steelmaking Flowlines

31. EAF ProcessFlow Diagram

32. Steelmaking made simple
Blast Furnace Oxygen Steelmaking Secondary Steelmaking
Electric Arc Steelmaking Continuous Casting
Iron Ore
Coal/Coke
Natural gas
Oil
Electricity
Steel scrap
Coal/Coke
Electricity
Natural Gas
Steel scrap

33. STEEL SECTOR