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Annotation About the Book: Now that India is virtually the only player in this field, an elaboration is needed with respect to more fundamental understanding as well as future prospects and needs, which this edition has tried to fulfill. It can now fulfill the need of a reference textbook in alternate iron making area for undergraduate and post graduate students in Metallurgical, Production, Manufacturing, Chemical, Materials and to a minor extent Mechanical Engineering disciplines. The aim of fulfilling the needs of entrepreneurs and plant operators has not only been retained; it has been elaborated. Further, the basic aspects have been presented in a way that is lucid and simple to understand and should serve as an incentive to the operators and entrepreneurs to develop a deeper understanding of the process. The project engineering section now gives guidelines sufficient to make a project report. Opportunities available to this process and the competition it faces has also been highlighted. A chapter on reaction kinetics has been included as also a section on iron ore and pellets. Other sections included are on Aerodynamics, Auto Ignition, Coal Throwing, etc. Rest of the text has been updated to the extent possible. Some advanced features have been introduced such as Mathematical Modeling, Computational Fluid Dynamics, Reduction Mechanism, etc. to give researchers in the area of food for thought. Contents: IntroductionRotary Kiln Process of Making Sponge IronThermodynamic Considerations: Feasibility of ReactionAerodynamics inside a Sponge Iron Rotary KilnMathematical Modelling in Rotary Kiln Sponge Iron MakingPhysical Movement of Solids inside a Rotary Kiln: Charge Movement and Coal Throwing/SlingingRequirement, Generation and Transfer of Heat in a Sponge Iron Rotary KilnReaction KineticsRaw Materials for Sponge Iron MakingAccretion or Ring Formation inside a Rotary KilnSponge Iron Properties: Re-oxidation and Auto-Ignition of Sponge IronUses of Sponge IronProcess Design, Engineering & Operational Aspects of an RK-DR PlantOther Uses of Rotary Kiln for Reduction PurposesEnvironmental Aspects of Sponge Iron Making in Rotary Kiln and Future Prospect.
This book focuses on agglomeration, or the size enlargement process, of iron ores. This process sits at the interface of mineral processing and extractive metallurgy. The book begins with a discussion of raw materials preparation and the beneficiation process. It then describes fundamental principles of the sintering and pelletization processes, including formation of green mix through granulation and green balls as well as chemical reactions during sintering. Finally, it offers a brief description of iron making processes and correlations related to the agglomerates: quality parameters and BF productivity and coke rate.
This comprehensive book deals with the environmental aspects of metallurgical industries, including ferrous (iron and steel, DRI units, EAF units, ferroalloys and foundries) and non-ferrous (aluminium, copper, lead and zinc) plants. The text, comprising of eight chapters, discusses fundamental aspects of environment management, various energy sources available on the earth and environment awareness required for sustained economic growth. The book provides a thorough understanding of pollution sources in metallurgical industries and their abatement techniques. It also provides details of energy management in metal industry and enumerates factors for metallurgical plant location and layout. Furthermore, it presents health and safety guidelines for metallurgical professionals. The text concludes with discussion on basic legislations related to environment and labour. This book is primarily designed for undergraduate students of metallurgical engineering. Besides, it will also be useful as a ready reference source to professionals associated with metallurgical industries. KEY FEATURES Coverage of various types of environmental issues such as air emission, toxic effluents, solid waste, thermal discharge, noise and radiation. Analysis of renewable and non-renewable energy sources on the earth with current energy usage pattern and future consumption pattern. Description of various activities in the metallurgical units along with discussion of sources of pollution and abatement techniques. Guidelines for the plant location and layout. Basic information about labour health and safety, environmental legislations, labour laws, ISO 14000, carbon credit, etc.
With a boom in the steel industry all over the world today, the demand of sponge iron has considerably increased as a feed (raw) material to steel making. The increase in the demand of sponge iron is also due to the fact that it is used for replacing coke making required for blast furnace processing. The primary objective of this book is to provide the basis, principles, fundamentals and theory of sponge iron production. This book, earlier titled as Sponge Iron Production in Rotary Kiln, is revised as per the feedback from students, faculty members and professionals. It, now, covers broad spectrum of alternative routes of iron making, therefore, the book is renamed as Alternative Routes to Iron Making. In this revised edition of the book, three new chapters have been added to fulfil the requirement of a textbook for various universities. NEW TO THIS EDITION • New chapters on: o Utilization of Sponge Iron o Environmental Pollution and Control in Sponge Iron Industries o Smelting Reduction Process • Inclusion of principle of fluidisation in fluidised bed processes • Description of Hyl III process with recent development of the process Primarily intended for undergraduate and postgraduate students of metal-lurgical engineering, this book is equally beneficial for researchers, and professionals engaged in DR processes and steel industries.
This book presents the fundamentals of iron and steel making, including the physical chemistry, thermodynamics and key concepts, while also discussing associated problems and solutions. It guides the reader through the production process from start to finish, covers the raw materials, and addresses the types of processes and reactions involved in both conventional and alternative methods. Though primarily intended as a textbook for students of metallurgical engineering, the book will also prove a useful reference for professionals and researchers working in this area.
The first of many important works featured in CRC Press’ Metals and Alloys Encyclopedia Collection, the Encyclopedia of Iron, Steel, and Their Alloys covers all the fundamental, theoretical, and application-related aspects of the metallurgical science, engineering, and technology of iron, steel, and their alloys. This Five-Volume Set addresses topics such as extractive metallurgy, powder metallurgy and processing, physical metallurgy, production engineering, corrosion engineering, thermal processing, metalworking, welding, iron- and steelmaking, heat treating, rolling, casting, hot and cold forming, surface finishing and coating, crystallography, metallography, computational metallurgy, metal-matrix composites, intermetallics, nano- and micro-structured metals and alloys, nano- and micro-alloying effects, special steels, and mining. A valuable reference for materials scientists and engineers, chemists, manufacturers, miners, researchers, and students, this must-have encyclopedia: Provides extensive coverage of properties and recommended practices Includes a wealth of helpful charts, nomograms, and figures Contains cross referencing for quick and easy search Each entry is written by a subject-matter expert and reviewed by an international panel of renowned researchers from academia, government, and industry. Also Available Online This Taylor & Francis encyclopedia is also available through online subscription, offering a variety of extra benefits for researchers, students, and librarians, including: Citation tracking and alerts Active reference linking Saved searches and marked lists HTML and PDF format options Contact Taylor and Francis for more information or to inquire about subscription options and print/online combination packages. US: (Tel) 1.888.318.2367; (E-mail) [email protected] International: (Tel) +44 (0) 20 7017 6062; (E-mail) [email protected]
Recent Advances in Mining and Processing of Low-Grade and Submarginal Mineral Deposits reviews advances in the mining and processing of low-grade and submarginal mineral deposits, taking into account the environmental considerations that increasingly are being regarded as a necessary prerequisite to acceptable mineral resources development. The focus is on marginal and sub-marginal ores, as well as ores of above normal cut-off grades which for some reason cannot be mined and/or processed economically at current technological or economic levels. This book is comprised of 12 chapters and begins with an overview of low-grade ore potential, followed by a discussion on the theoretical and practical aspects of in situ mining. Block cave-in place leaching, biological leaching of sulfide ores, and nuclear chemical mining of primary copper sulfides are also considered. Subsequent chapters explore the economics and safety of nuclear chemical copper mining; hydrometallurgy of low-grade copper ores; trends in process metallurgy; and environmental aspects of mining and processing low-grade and submarginal mineral deposits. This monograph should be of interest to mining officials and professionals.
Rotary Kilns—rotating industrial drying ovens—are used for a wide variety of applications including processing raw minerals and feedstocks as well as heat-treating hazardous wastes. They are particularly critical in the manufacture of Portland cement. Their design and operation is critical to their efficient usage, which if done incorrectly can result in improperly treated materials and excessive, high fuel costs. This professional reference book will be the first comprehensive book in many years that treats all engineering aspects of rotary kilns, including a thorough grounding in the thermal and fluid principles involved in their operation, as well as how to properly design an engineering process that uses rotary kilns.Chapter 1: The Rotary Kiln Evolution & PhenomenonChapter 2: Basic Description of Rotary Kiln OperationChapter 3: Freeboard Aerodynamic PhenomenaChapter 4: Granular Flows in Rotary KilnsChapter 5: Mixing & SegregationChapter 6: Combustion and FlameChapter 7: Freeboard Heat TransferChapter 8: Heat Transfer Processes in the Rotary Kiln BedChapter 9: Mass & Energy BalanceChapter 10: Rotary Kiln Minerals Process Applications·Covers fluid flow, granular flow, mixing and segregation, and aerodynamics during turbulent mixing and recirculation·Offers hard-to-find guidance on fuels used for rotary kilns, including fuel options such as natural gas versus coal-fired rotary kilns·Explains principles of combustion and flame control, heat transfer and heating and material balances
Written in a student-friendly manner, the book begins with the introduction to fuels, furnaces and refractories. It further exposes the reader to the different types of fuels with their testing methods. Besides covering the recent developments in the field of non-recovery coke ovens, dry coke cooling, use of coal in DRI and blast furnace, and new energy recovery system, the book also covers all the aspects of refractory systems. For better understanding of the text, the book includes a large number of illustrations. The book also facilitates a thorough understanding of different environmental issues associated with the use of fuel. Finally, the reader is made familiar with the Indian industrial scenario regarding fuels, furnaces and refractories.
This book provides a fascinating study of the very important emerging field of direct reduction in which iron ore is ‘directly reduced’ in the solid-state, using either natural gas or non-coking coal, to produce a highly metallised material, referred to as sponge iron (or direct reduced iron). This intermediate product is subsequently melted in electric arc furnaces or induction furnaces (sometimes even in basic oxygen furnaces) to produce liquid steel. Such a process combination enables steel to be produced without using coking coal, which is an expensive input in the normal blast furnace—basic oxygen furnace route of steelmaking adopted in integrated steel plants. The book offers comprehensive coverage and critical assessment of various coal-based and gas-based direct reduction processes. Besides dealing with the application of the theoretical principles involved in the thermodynamics and kinetics of direct reduction, the book also contains some worked-out examples on sponge iron production. The concluding part of this seminal book summarises the present and future scenario of direct reduction, including the use of gas generated from coal in direct reduction processes. The book is primarily intended for the undergraduate and postgraduate students of metallurgical engineering. It is also a must-read for researchers, technologists and process metallurgists engaged in the rapidly developing field of direct reduction of iron oxides, which is of critical importance for India and other developing nations that are beginning to play a major role in global steelmaking.