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​This book describes the available technologies that can be employed to reduce energy consumption and greenhouse emissions in the steel- and ironmaking industries. Ironmaking and steelmaking are some of the largest emitters of carbon dioxide (over 2Gt per year) and have some of the highest energy demand (25 EJ per year) among all industries; to help mitigate this problem, the book examines how changes can be made in energy efficiency, including energy consumption optimization, online monitoring, and energy audits. Due to negligible regulations and unparalleled growth in these industries during the past 15-20 years, knowledge of best practices and innovative technologies for greenhouse gas remediation is paramount, and something this book addresses. Presents the most recent technological solutions in productivity analyses and dangerous emissions control and reduction in steelmaking plants; Examines the energy saving and emissions abatement efficiency for potential solutions to emission control and reduction in steelmaking plants; Discusses the application of the results of research conducted over the last ten years at universities, research centers, and industrial institutions.
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 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.
As product specifications become more demanding, manufacturers require steel with ever more specific functional properties. As a result, there has been a wealth of research on how those properties emerge during steelmaking. Fundamentals of metallurgy summarises this research and its implications for manufacturers.The first part of the book reviews the effects of processing on the properties of metals with a range of chapters on such phenomena as phase transformations, types of kinetic reaction, transport and interfacial phenomena. Authors discuss how these processes and the resulting properties of metals can be modelled and predicted. Part two discusses the implications of this research for improving steelmaking and steel properties.With its distinguished editor and international team of contributors, Fundamentals of metallurgy is an invaluable reference for steelmakers and manufacturers requiring high-performance steels in such areas as automotive and aerospace engineering. It will also be useful for those dealing with non-ferrous metals and alloys, material designers for functional materials, environmentalists and above all, high technology industries designing processes towards materials with tailored properties. - Summarises key research and its implications for manufacturers - Essential reading for steelmakers and manufacturers - Written by leading experts from both industry and academia
This book describes improvements in the iron and steel making process in the past few decades. It also presents new and improved solutions to producing high quality products with low greenhouse emissions. In addition, it examines legislative regulations regarding greenhouse emissions all around the world and how to control these dangerous emissions in iron and steel making plants.
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.
Contributed articles presented at the Conference.
Blast Furnace Ironmaking: Analysis, Control, and Optimization uses a fundamental first principles approach to prepare a blast furnace mass and energy balance in ExcelTM. Robust descriptions of the main equipment and systems, process technologies, and best practices used in a modern blast furnace plant are detailed. Optimization tools are provided to help the reader find the best blast furnace fuel mix and related costs, maximize output, or evaluate other operational strategies using the ExcelTM model that the reader will develop. The first principles blast furnace ExcelTM model allows for more comprehensive process assessments than the 'rules of thumb' currently used by the industry. This book is suitable for undergraduate and postgraduate science and engineering students in the fields of chemical, mechanical, metallurgical and materials engineering. Additionally, steel company engineers, process technologists, and management will find this book useful with its fundamental approach, best practices description, and perspective on the future. - Provides sample problems, answers and assignments for each chapter - Explores how to optimize the blast furnace operation while maintaining required temperatures and gas flowrates - Describes all major blast furnace equipment and best practices - Features blast furnace operating data from five continents