Ferrous Metallurgy

Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

For a reaction to take place spontaneously,

the free energy of the products must be lower than
the free energy of the reactants.
i.e. ∆G must be negative.
We know that

∆G = ∆H – T∆S
Where,

∆G = Change in free energy

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ ∆H = Change in enthalpy
∆S = Change in entropy
… Vision 2050 …

T = temperature
To be ∆G negative, there should be
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decrease in enthalpy and increase in entropy of the system.
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Reactions Kinetics

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Concentration
of reactants
State of
reactants and system Temp.
their ability to & Pressure
meet

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Chemical Factors
… Vision 2050 …
nature of Affecting Catalyst
reactants RoR*

* RoR : Rate of Reaction

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Titrimetric

Reactions
Initial rate colorimetr
method
mix. ic
analyzing

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Conducti
metric

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

COLLISION
THEORY

Theories of reactions rate

TRANSITION STATE
THEORY

DETAILED DYNAMICAL
THEORY
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
THEORIES OF REACTIONS
IN SOLUTION

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Products

Reactants

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

The change of concentration in a system can generally be acquired in
… Vision 2050 … two ways:
By monitoring the depletion of reactant over time, or
By monitoring the formation of product over time
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Change in concentration = final concentration – initial concentration

Rate of reaction = change of concentration / change in time

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

The term :-

Chemical kinetics refers to the branch of physical

chemistry that deals with the rates of chemical reactions.

Thermodynamics refers to the branch of physical

science that deals with the relations between heat and other
forms of energy such as
mechanical energy, or….
electrical energy , or ….
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
chemical energy
… Vision 2050 …

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Salient kinetic features that need to be noted are as follows:

Lump ore, sinter and pellets are porous solids. Reduction is characterized by
the formation of a porous product layer.
Fe₂O₃ is reduced in stages viz,
Fe₂O₃ → Fe₃O₄ → FeₓO → Fe
Additional porosity develops during reduction owing to density differences of
the product solids.
The relative volume per unit mass of Fe are:
Fe :Fe2O3 : Fe₃O₄ : Fe₂O₃ = 1 : 1.79 : 2.08 : 2.14 As a result,
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ when hematite is reduced to magnetite, additional porosity develops,
enhancing further reduction of hematite.
… Vision 2050 …
A measure of rate of reduction (r₀) is dF₀/dt, where t is the time after
reduction starts.
The higher the reducibility of an iron oxide bearing solid, the faster is the
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reduction of reduction.
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

The kinetic steps involved are

1. Transfer of reactant gas to the solid surface (CO or H₂) across the gas
boundary layer around the piece of solid.

2. Inward diffusion of reactant gas through the pores of the solid.

3. Chemical reactions occurring are:

FeO(s) + CO(g) = Fe(s) + CO₂(g) FeO(s) + H₂(g) = Fe(s) + H₂O(g)

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
4. Outward diffusion of the product gas (CO₂ or H₂O) through the pores.
… Vision 2050 …

5. Transfer of the product gas from the solid surface into the bulk gas
across the boundary layer.
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

The rates of the above reactions are comparable.

The overall rate depends on:-

1. Temperature
2. Gas Composition
3. Size of the particle
4. Nature of the solid in terms of its structure and composition.

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… Vision 2050 …

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

The pattern of ore reduction has been classified into:-

I. Uniform internal reduction

Chemical Reaction < Diffusion through pores

II. Topochemical reduction with a sharp interface

Chemical Reaction > Diffusion through pores
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
III. Topochemical reduction with diffused interface
… Vision 2050 … Chemical Reaction ≈ Diffusion through pores

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

Fe grains Fe layer Reaction zone

Oxide Oxide

(a) Internal reduction (b) Topochemical reduction (b) Topochemical reduction

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
With shape interface With diffused interface
… Vision 2050 …
Sketches of sections of partially reduced iron ore pellets , show 3 patterns
( Fe2O3 , Fe3O4 and FeO have not shown separately )

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

The overall kinetics of iron ore reduction is

a. Dependence of the rate on the structure of the solid,

especially its porosity and pore structure.

b. Changes in overall structure of the solid during

reduction on account of swelling/ contraction, recrystallization and grain growth.

c. Comparable rates of chemical reaction, pore diffusion and in

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ many cases, boundary layer mass transfer
… Vision 2050 …

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad
 Ferrous Metallurgy
Postgraduate
Prof. Dr. Mohamed Mraikab , Dr. Sanaa Abd Almoaamen Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
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Eng. Dr. Hesham Saad