Modern iron making handbook
By: R.H. Tupkary, V.R. Tupkary
Series: MLI handbook series; MLI handbook series
Publisher: Mercury Learning & Information
Published: 2018
Place of publication: Dulles, Virginia
Language: eng
Number of pages: 492
ISBN-13: 9781523114467; 9781683921363
Subjects: Iron; Metallurgy; Fer; Métallurgie
Description: This book comprehensively deals with all of the key topics of iron making including blast furnace plants, operations and processes, raw materials, preparation, chemical processes, and more.
Notes: Includes bibliographical references and index.
Table of contents: title: Machine generated contents note: 1.1. Ancient Ironmaking; title: 1.2. Historical Ironmaking Processes; title: 1.3. Developments that Led to Modern Ironmaking; title: Coke Furnace; title: Hot Blast Generation; title: Blast Furnace Gas Cleaning; title: Charging Devices; title: Pig Casting Machine; title: 1.4. Modern Ironmaking; title: 1.5. Alternative Methods of Iron Production; title: 1.6. History of the Iron and Steel Industry in the United States; title: 1.7. Twenty-first Century Trends (U.S. and the World); title: U.S. Production of Selected Mineral Commodities in the First Quarter 2017; title: 1.8. Concluding Remarks; title: 2.1. Introduction; title: 2.2. Modern Blast Furnace; title: Furnace Details; title: 2.3. Hot Blast Stove; title: 2.4. Gas Cleaning; title: 2.5. Raw Materials Storage and Handling; title: 2.6. Liquid Products Disposal; title: Hot Metal Ladles; title: 2.7. Blast Furnace Operation and Control; title: 2.8. Essentials of the Blast Furnace Process; title: Stack or Shaft; title: Bosh; title: Tuyere or Combustion Zone; title: Hearth; title: 2.9. Efficiency of Blast Furnace; title: 2.10. Concluding Remarks; title: Note continued: 3.1. Introduction; title: 3.2. Iron Ores; title: World Deposits of Iron Ores; title: 3.3. Metallurgical Coal; title: Metallurgical Coal Reserves; title: 3.4. Limestone and Dolomite as Flux; title: 3.5. Concluding Remarks; title: 4.1. Introduction; title: 4.2. Functions of Coke; title: 4.3. Quality Requirements of Coke; title: Reactivity; title: Size; title: Strength and Abrasion Resistance; title: Micum Test; title: ASTM Tumbler Test (U.S.); title: Preparation of BF Fuel; title: 4.4. Preparation of Coke (India); title: Coal Ranking (U.S.); title: 4.5. Modifications in Coke Making Practices; title: Stamp Charging of Coke Ovens; title: Economizing Coke-Charge-Mix; title: Use of Waste Plastic in Coke Making; title: 4.6. Alternative Fuels; title: 4.6. Ferro-coke; title: 4.7. Concluding Remarks; title: 5.1. Introduction; title: 5.2. Elements of Distribution; title: 5.3. Factors Affecting Distribution; title: Factors Affecting Distribution Inside the Furnace; title: Angle and Size of the Big Bell; title: Angle of Repose and Shape of Particles; title: Order of Charging; title: 5.4. Limitations; title: 5.5. Concluding Remarks; title: Note continued: 6.1. Introduction; title: Lumps; title: Coarse Fines; title: Very Fine Fines; title: 6.2. Burden Qualities; title: Physical; title: Chemical; title: 6.3. Crushing and Sizing; title: 6.4. Beneficiation of the Iron Ores; title: Magnetic Concentration; title: Gravity Methods; title: Flotation Method; title: Electrostatic Separation; title: Magnetic Roasting; title: Washing; title: Drying; title: 6.6. Calcining/Roasting; title: 6.7. Blending; title: 6.8. Shipping; title: 6.9. Products of Ore Processing; title: 6.10. Treatment of Iron Ores (India); title: Ore Treatment at Tata Steel; title: Alumina Problem and Beneficiation; title: Treatment of Goa Ores; title: Kundremukh Iron Ore Project; title: 6.11. Agglomeration of Iron Ores; title: Briquetting; title: Nodulizing; title: Vacuum Extrusion; title: Sintering; title: Pelletizing; title: 6.12. World Resources (2017 USGS); title: Substitutes; title: 6.13. Concluding Remarks; title: 7.1. Principle of Sintering; title: 7.2. Process Variables; title: 7.3. Sinter Quality; title: 7.4. Mechanism of Sintering; title: 7.5. Raw Material Requirements; title: Size; title: Fuel Content; title: Moisture; title: Circulating Load; title: Note continued: Performance of Sintering Machine; title: Economics; title: 7.6. Recent Trends in Sintering Practice; title: 7.7. Alumina Problem in Sintering; title: Indian Scenario; title: 7.8. Concluding Remarks; title: 8.1. Introduction; title: 8.2. The Pelletization Process; title: 8.3. Theory of Bonding; title: 8.4. Mechanism of Ball Formation; title: Nucleii Growth Region; title: Transition Period; title: Ball Growth Region; title: Growth by Assimilation; title: Growth by Layering; title: 8.5. Feed Size, Shape, and Porosity; title: 8.6. Green Ball Production; title: Disc Pelletizer; title: Drum Pelletizer; title: 8.7. Additives; title: 8.8. Induration of Pellets; title: Drying; title: Preheating and Firing; title: Firing Units; title: 8.9.Comparison of the Pellet Firing Machines; title: 8.10. Indian Pelletization Plants; title: 8.11.U.S. Production (Pelletization); title: 8.12. Concluding Remarks; title: 9.1. Introduction; title: 9.2. Room Temperature Physical Properties; title: Shatter Tests; title: Tumbling and Abrasion Test; title: Compression Test; title: Porosity; title: 9.3. Reducibility; title: Note continued: 9.4. Physical Behavior of Materials During Reduction at High Temperatures; title: Decrepitation; title: Low-Temperature Breakdown Test (L.T.B.T.); title: Reduction Degradation Index Test (R.D.I); title: Reducibility Test (R.I.) on Iron Bearing Materials; title: Coke Reactivity Test (C.R.I.) and Coke Strength after Reaction (C.S.R.); title: Hot Compression Strength; title: Swelling; title: Softening of Materials in the Blast Furnace; title: High Temperature Permeability Under Reducing Conditions and Applied Load; title: 9.5. Concluding Remarks; title: 10.1. Introduction; title: 10.2. The Blast Furnace Profiles; title: Thermal, Physical, and Chemical Profiles; title: Physical Structure; title: 10.3. Thermodynamic Equilibria; title: Carbon-Oxygen Equilibria; title: Equilibria in Fe-C-O and Fe-O-H Systems; title: Elements of Stoichiometry; title: 10.4. Physical Chemistry of Blast Furnace Process; title: Reactions in the Tuyere Zone; title: Reactions in Stack; title: Kinetics of Iron Oxide Reduction; title: Physical Nature of Ore and Its Previous History; title: Note continued: Nature and Composition of Gangue in the Charge; title: Temperature and Carbon Monoxide Content of Gases; title: Chemical Nature of Iron Oxide; title: Pressure; title: Solid-Solid Reaction; title: Reactions in the Bosh; title: Reactions in the Hearth; title: Sulphur Reaction; title: 10.5. Alumina Problem; title: Indian Ores; title: 10.6. Kinetics of Reactions in Bosh and Hearth; title: 10.7. Efficiency of the Blast Furnace Process; title: Elements of Enthalpy Balance; title: Process Zones in a Blast Furnace; title: Thermal Efficiency; title: 10.8. Quality of Hot Metal; title: Silicon Content of Hot Metal; title: 10.9. TiO2 Addition in Burden; title: 10.10.U.S. and World Events, Trends, and Issues. Source: USGS 2017; title: Recycling; title: Import Sources (2012-15); title: Trends and Issues; title: World Mine Production and Reserves; title: 10.11. Concluding Remarks; title: 11.1. Blast Furnace Refractories; title: Stack Lining; title: Hearth Lining; title: Hearth Walls; title: Bosh Lining; title: Carbon-lined Furnaces; title: 11.2. Blast Furnace Structure; title: 11.3. Blast Furnace Cooling Arrangements; title: Note continued: Shaft Coolers; title: Hearth and Bosh Coolers; title: Cooling of Hearth Bottom; title: 11.4. Tap Holes; title: 11.5. Cast House; title: 11.6. Tuyere Assembly; title: 11.7. Raw Material Section; title: 11.8. Charge Hoisting Appliances; title: 11.9. Top Charging System; title: 11.10. Blowers, Boilers, Pumps, etc; title: 11.11. Slag-granulation; title: 11.12. Instrumentation and Control; title: 11.13. Concluding Remarks; title: 12.1. Uptake, Downcomer, and Bleeder; title: 12.2. Dust Catcher; title: 12.3. Semi-Fine or Primary Cleaning; title: Scrubbers or Spray Towers; title: Venturi Washer; title: 12.4. Fine or Secondary Cleaning; title: Electrostatic Precipitator (ESP); title: 12.5. Utilization of Blast Furnace Gas; title: 12.6. Hot Blast Stove; title: Construction of the Stove and Its Accessories; title: 12.7. Concluding Remarks; title: 13.1. Blowing-in; title: Drying; title: Filling; title: Lighting and Operating Until Routine Practice is Established; title: 13.2. Banking; title: 13.3. Blowing-out; title: 13.4. Tapping; title: 13.5. Fanning; title: 13.6. Back Drafting; title: 13.7. Conclusions; title: 14.1. Hanging; title: Remedies; title: Note continued: 14.2. Scaffolding; title: 14.3. Slip; title: 14.4. Chilled Hearth; title: 14.5. Pillaring; title: 14.6. Breakout; title: 14.7. Choking of Gas Offtake; title: 14.8. Flooding and Coke Ejection Through the Tap Hole; title: 14.9. Leaking Tuyeres, Tap Holes, and Coolers; title: 14.10. Channeling; title: 14.11. Salamander Formation; title: 14.12. Concluding Remarks; title: 15.1. Introduction; title: 15.2.Composition of Pig Iron; title: 15.3. Slag Composition; title: Slag Volume; title: How to Calculate the Slag Volume?; title: Disposal of Slag; title: 15.4. Production of Ferro-Manganese; title: 15.5. The Sulfur Problem; title: 15.6. Basic Burdening of Blast Furnace and External Desiliconization; title: 15.7. Acid Burdening of Blast Furnace and External De sulfurization; title: Indian Practice of Acid Burdening; title: 15.8. Disposal of Metal; title: 15.9. Concluding Remarks; title: 16.1. Introduction; title: 16.2. Burden Distribution; title: 16.3. Burden Trajectory and Profiles; title: 16.4. Burden Distribution Patterns; title: 16.5. Blast Furnace Performance; title: 16.6. Effect of Sizing; title: Note continued: 16.7. Use of Agglomerate as Burden; title: Sinter; title: Pellets; title: 16.8. Sinter vs. Pellets; title: 16.9. Agglomerate vs. Natural Lumpy Ore; title: 16.10. Sizing of Coke and Its Quality; title: 16.11. Flux Quality; title: 16.12. Concluding Remarks; title: 17.1. Introduction; title: 17.2. Large-Capacity Blast Furnaces; title: 17.3. Coke Quality; title: 17.4. Burden Preparation; title: 17.5. Improved Distribution of Charge; title: Stock-line Armor; title: 17.6. High Top Pressure; title: 17.7. Charging Devices for High Top Pressure; title: Tops with Only Bells; title: Paul-Wurth/CRM Top; title: NKK's Four Bell Top; title: Tops with Bells and Valve Seals; title: Bell Construction and Operation; title: Top with Only Valve Seals (No Bells); title: Gimble Top Distributor; title: 17.8. Higher Blast Temperature and Driving Rate; title: 17.9. Oxygen Enrichment of Blast; title: 17.10. Humidification of Blast; title: 17.11. Fuel Injection; title: Pulverized Coal Injection; title: 17.12. Lime Injection; title: 17.13. Pre-reduced Ore as Burden; title: 17.14. Injection of Reducing Gas at the Bottom of the Stack; title: Note continued: 17.15. Utilization of Plant Iron-Bearing Wastes; title: 17.16. Concluding Remarks; title: 18.1. Introduction; title: 18.2. Process Variables; title: Variety of Operational Variables; title: 18.3. Probes for Measuring the Process Variables; title: 18.4. BF Operational Models; title: 18.5. Process Control Strategies; title: Overall Control Strategy; title: 18.6. Central Working Index; title: 18.7. Advantages of Process Control; title: 18.8. Concluding Remarks; title: 19.1. Introduction; title: 19.2. The Low-Shaft Furnace; title: 19.3. Mini-Blast Furnaces (MBFs); title: Special Features of MBF; title: Modern MBFs; title: Chinese MBF; title: First MBF in India; title: Charcoal Blast Furnace; title: 19.4. Concluding Remarks; title: 20.1. General; title: 20.2. Historical; title: India; title: 20.3. The Submerged Arc Furnace Plant; title: 20.4. Operation; title: 20.5. Smelting Practice; title: 20.6. Modern Trends; title: 20.7. Special Features; title: 20.8. Irregularities in Operations; title: 20.9. Concluding Remarks; title: 21.1. Introduction; title: 21.2. Physical Chemistry of DR Processes; title: 21.3. Sponge Ironmaking Processes; title: Note continued: HyL Process; title: 21.4. Midrex Process; title: Other Gaseous Reduction Processes; title: Gas-based Processes; title: 21.5. Fluidized Bed Processes; title: 21.6. Coal-Based DR Processes; title: General Design Features; title: Raw Materials; title: Product; title: Ring Formation in a Rotary Kiln; title: Coal-based Process Designs; title: Process Control; title: 21.7. Coal-Based Shaft Furnaces; title: 21.8. Gasified Coal-Based Processes; title: 21.9. Sponge Iron Production in India; title: 21.10. Metallurgical Properties of Sponge Iron; title: 21.11. Use of Sponge Iron; title: 21.12. Concluding Remarks; title: 22.1. Introduction; title: 22.2. Classification of SR Processes; title: 22.3. Thermo-chemical Model; title: 22.4. Vertical Shaft Furnace Processes; title: Corex Process; title: Sumitomo SC Process; title: Kawasaki Process (SR); title: Finex Process; title: Technored Process; title: 22.5. Electrical Processes; title: INRED Process; title: ELRED Process; title: COMBISMELT Process; title: Plasmasmelt Process; title: Fastmelt Process; title: 22.6. Converter Processes; title: Krupp-COIN Process; title: PCIG Process; title: HI-Smelt Process; title: Note continued: Reactor Steelmaking Process; title: AISI-HyL Direct Steelmaking; title: 22.7. Bath Smelting Processes; title: Romelt (Earlier FLPR) Process; title: DIOS (Direct Iron Ore Smelting Process); title: 22.8. Rotary Hearth Furnace Processes (RHF); title: IT mk3 Process; title: 22.9. TUPKARY-SR Process; title: 22.10. Concluding Remarks.