MM2303

IRON MAKING
3 credits [3-0-0]

Coordinator: Prof. Anshuman Patra

Course Outcome:

1. Understanding of overall blast furnace operations and design.

2. Understanding of Raw Materials and their properties in Ironmaking.

3. Understanding of Agglomeration process in Ironmaking.

4. Comprehension of physicochemical principles involved in ironmaking.

5. Understanding of blast furnace slag and the effect on final hot metal quality.

6. Factors for improving blast furnace productivity.

Syllabus

Raw materials and their properties: Iron ore, Limestone, Agglomerates and Coke,
Beneficiation of Iron ores. Preparation of ores: sintering and palletizing, blast furnace
burdening and distribution, testing of raw materials for blast furnace. Design: Blast furnace
profile, stove and gas cleaning units instrumentation, refractory used in blast furnace and
stove. Reactions: Fe-C-O, Fe-O-H phase equilibria, Reactions in stack, bosh and hearth
formation of primary slag, bosh slag and hearth slag. Slag composition and its control, Metal-
slag reactions, Control of hot metal composition. Process Control: Factors affecting fuel
consumption and productivity, Recent developments in Blast furnace operations like, Bell-
less top charging system, High top pressure, Humidified & Oxygen enriched blast and
Auxiliary fuel injection through tuyers.

Irregularities in blast furnace operation and their remedies.Alternative routes of iron making:
Introduction, Processes of Sponge Iron production SL/RN, MIDREX, HyL processes.
Smelting Reduction Processes COREX, ROMELT, Hismelt.

Essential Reading:
1. A. K. Biswas, Principles of Blast Furnace Iron Making, SBA publication, Calcutta, 1999.
2. Ahindra Ghosh, Ironmaking and Steelmaking Theory and Practice, The AISE Steel
Foundation, 2004

Supplementary Reading:
1. A.Ghosh and A.Chatterjee, Ironmaking and Steelmaking Theory and Practice, Prentice-
Hall of India Private Limited, 2008
2. Ian Cameron, Mitren Sukhram, Kyle Lefebvre, William Davenport, Blast Furnace
Ironmaking Analysis, Control, and Optimization, Elsevier Science, 2019
Course Plan :
Module 1 : No. of classes: 6
Raw materials and their properties: Iron ore, Limestone, Agglomerates and Coke.

Module 2 : No. of classes: 4

Beneficiation of Iron ores. Preparation of ores: sintering and pelletizing

Module 3 : No. of classes: 3

Blast furnace burdening and distribution

Module 4 : No. of classes: 3

Testing of raw materials for blast furnace

Module 5 : No. of classes: 4

Design: Blast furnace profile, stove and gas cleaning units instrumentation, refractory used in
blast furnace and stove.

Module 6 : No. of classes: 5

Reactions: Fe-C-O, Fe-O-H phase equilibria, Reactions in stack, bosh and hearth formation
of primary slag, bosh slag and hearth slag. Slag composition and its control, Metal-slag
reactions, Control of hot metal composition.

Module 7 : No. of classes: 2

Process Control: Factors affecting fuel consumption and productivity,

Module 8 : No. of classes: 4

Recent developments in Blast furnace operations like, Bell-less top charging system, High
top pressure, Humidified & Oxygen enriched blast and Auxiliary fuel injection through
tuyers.

Module 9 : No. of classes: 2

Irregularities in blast furnace operation and their remedies.

Module 10 : No. of classes: 3

Alternative routes of iron making: Introduction, Processes of Sponge Iron production SL/RN,
MIDREX, HyL processes. Smelting Reduction Processes COREX, ROMELT, Hismelt.

Total classes (without test): 36