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Treatise on process metallurgy. Volume 3, Industrial processes /

This treatise provides a comprehensive overview of industrial processes in the field of process metallurgy. Edited by experts from prestigious institutions, it covers a broad range of topics including the metallurgy of iron and steelmaking, extraction of nonferrous metals, and the development of new...

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Bibliographic Details
Corporate Author: ScienceDirect (Online service)
Other Authors: Seetharaman, Seshadri
Format: eBook
Language:English
Published: Amsterdam : Elsevier, 2024.
Edition:Second edition.
Subjects:
Metallurgy.
Manufacturing processes.
Production engineering.
Métallurgie.
Fabrication.
Technique de la production.
metallurgy.
manufacturing.
Electronic books.
Online Access:Connect to the full text of this electronic book
Table of Contents:
  • Intro
  • Treatise on Process Metallurgy: Volume 3: Industrial Processes
  • Copyright
  • Obituary
  • Contents
  • Contributors
  • Editors Biographies
  • Preface to the 2nd Edition
  • Preface to the 1st Edition
  • Section 1: Iron and Steel Technology
  • Chapter 1.1: Iron and Steelmaking-Introduction
  • Chapter 1.2: Ironmaking
  • 1.2.1. INTRODUCTION
  • 1.2.1.1. Modern Ironmaking Processes in Brief
  • 1.2.1.1.1. Ironmaking as Integrated Part in Steelmaking
  • 1.2.1.1.2. Blast Furnace Process Overview
  • 1.2.1.1.2.1. Charging
  • 1.2.1.1.2.2. Burden and Gas Movement
  • 1.2.1.1.2.3. Blast Furnace Zones and Principal Reactions
  • 1.2.1.1.2.4. Casting and Hot Metal Treatment
  • 1.2.1.1.2.5. Continuous Improvement in Ironmaking Blast Furnace
  • 1.2.1.1.3. Present Development and Alternative Ironmaking Technologies
  • 1.2.1.1.3.1. Direct Reduction (DR)
  • 1.2.1.1.3.2. Smelting Reduction (SR)
  • 1.2.1.1.3.3. New Developments
  • 1.2.1.2. Early History of Ironmaking
  • 1.2.1.2.1. Beginning of Blast Furnace Era
  • 1.2.1.2.2. Development to Present Days
  • 1.2.1.2.2.1. Reductant and Fuel: From Charcoal to Coke
  • 1.2.1.2.2.2. Ore Preparation: From Roasting to Sintering and Pelletizing
  • 1.2.1.2.2.3. Furnace Design Changes
  • 1.2.1.2.2.4. Preheating Blast With Top Gas
  • 1.2.2. RAW MATERIALS AND THEIR PREPARATION
  • 1.2.2.1. Iron-Bearing Materials and Additives
  • 1.2.2.1.1. Types of Iron Ores
  • 1.2.2.1.2. Agglomerates and Additives
  • 1.2.2.1.2.1. Sinter and Sintering Process
  • 1.2.2.1.2.2. Pellets and Pelletizing Process
  • 1.2.2.1.2.3. Briquettes
  • 1.2.2.1.2.4. Slag Formers in Agglomerates
  • 1.2.2.1.2.5. Additives in Blast Furnace
  • 1.2.2.1.2.6. DRI and Scrap
  • 1.2.2.2. Reducing Agents and Energy Sources
  • 1.2.2.2.1. Coke and Coke-Making
  • 1.2.2.2.1.1. Coking
  • 1.2.2.2.1.2. Coke Characterization
  • 1.2.2.2.2. Injectants
  • 1.2.2.2.2.1. Pulverized Coal.
  • 1.2.2.2.2.2. Plastics, Fluff, and Other Solids
  • 1.2.2.2.2.3. Oil and Tar
  • 1.2.2.2.2.4. Natural Gas
  • 1.2.2.2.2.5. Coke Oven Gas
  • 1.2.2.2.2.6. Hydrogen-Future Fossil-Free Reductant and Energy
  • 1.2.3. THE IRONMAKING BLAST FURNACE: FACILITIES AND PROCESSES
  • 1.2.3.1. Blast Furnace Facilities
  • 1.2.3.1.1. Construction and Profile
  • 1.2.3.1.2. Different Zones in a Blast Furnace
  • 1.2.3.1.3. Charging Equipment
  • 1.2.3.1.4. Lining and Cooling
  • 1.2.3.1.5. Evolution of Blast Furnace Dimension
  • 1.2.3.1.6. Auxiliary Units
  • 1.2.3.2. Blast Furnace Process and Operation
  • 1.2.3.2.1. Charging
  • 1.2.3.2.1.1. Bell Top Charging
  • 1.2.3.2.1.2. Bell-Less Top Charging
  • 1.2.3.2.2. Burden Descending and Physical-Chemical Changes
  • 1.2.3.2.2.1. Throat and Shaft
  • 1.2.3.2.2.2. Cohesive Zone
  • 1.2.3.2.2.3. Dripping Zone
  • 1.2.3.2.2.4. Active Coke Zone
  • 1.2.3.2.2.5. Raceway
  • 1.2.3.2.2.6. Hearth Coke and Deadman
  • 1.2.3.2.2.7. Hot Metal and Slag
  • 1.2.3.2.3. Movement of Gas
  • 1.2.3.2.3.1. Gas Supply and Gas Generation
  • 1.2.3.2.3.2. Ascending Flow
  • 1.2.3.3. Blast Furnace Process Control
  • 1.2.3.3.1. Process Control Structure
  • 1.2.3.3.2. Blast Furnace Instrumentation
  • 1.2.3.3.3. Application of Artificial Intelligence (AI) in Blast Furnace Control, Automation, and Optimization
  • 1.2.4. BLAST FURNACE REACTIONS
  • 1.2.4.1. Reactions in the Upper Zone
  • 1.2.4.1.1. Water Removal and Volatilization
  • 1.2.4.1.2. Preheating and Early Stage of Ore Reduction
  • 1.2.4.1.3. Decomposition of Carbonates
  • 1.2.4.1.4. Behavior of Volatile Compounds and Metals
  • 1.2.4.2. Reactions in the Middle Zones
  • 1.2.4.2.1. Chemical and Thermal Reserve Zone
  • 1.2.4.2.2. Indirect Reduction of Wüstite
  • 1.2.4.3. Reactions in the Lower Zones
  • 1.2.4.3.1. Calcination of Limestone
  • 1.2.4.3.2. Direct Reduction of Wüstite
  • 1.2.4.4. Deadman and Hearth.
  • 1.2.4.4.1. Functions of a Deadman
  • 1.2.4.4.2. Floating Deadman
  • 1.2.4.4.3. Inactive Deadman
  • 1.2.4.5. Behavior of Minor Elements and Impurities
  • 1.2.4.5.1. Behavior of Metallic Impurities
  • 1.2.4.5.1.1. Silicon
  • 1.2.4.5.1.2. Manganese
  • 1.2.4.5.1.3. Titanium
  • 1.2.4.5.1.4. Chromium
  • 1.2.4.5.2. Behavior of Nonmetallic Impurities P and S
  • 1.2.4.5.2.1. Phosphorus
  • 1.2.4.5.2.2. Sulfur
  • 1.2.4.5.3. Behavior of Circulating Elements
  • 1.2.4.5.3.1. Zinc
  • 1.2.4.5.3.2. Alkali Metals: Potassium and Sodium [31]
  • 1.2.4.6. Formation of Hot Metal and Slag
  • 1.2.4.6.1. Formation of Hot Metal
  • 1.2.4.6.2. Formation of Slag
  • 1.2.5. ENERGY CONSUMPTION, PROCESS PERFORMANCE, AND ENVIRONMENTAL CONTROL
  • 1.2.5.1. Energy Consumption and Distribution
  • 1.2.5.1.1. A Global Picture of Energy Consumption
  • 1.2.5.1.2. Energy and Materials Balance, and Energy Recovery
  • 1.2.5.1.2.1. Materials Balance
  • 1.2.5.1.2.2. Energy Balance
  • 1.2.5.1.2.3. Energy Recovery
  • 1.2.5.1.3. Blast Furnace Operating Conditions
  • 1.2.5.2. Blast Furnace Performance
  • 1.2.5.2.1. Gas Utilization Efficiency
  • 1.2.5.2.2. Blast Furnace Productivity and Performance
  • 1.2.5.3. Environmental Impacts and Recycling of Process Residues From Steelworks
  • 1.2.5.3.1. Environmental Impacts of Ironmaking
  • 1.2.5.3.2. Recycling of Process Residues From Ironmaking and Steelmaking [55]
  • 1.2.5.3.2.1. Solid Residues From Ironmaking and Steelmaking
  • 1.2.5.3.2.2. Main Challenges and Current Solutions
  • 1.2.5.3.2.3. Future Perspectives
  • 1.2.6. FUTURE TRENDS AND SUSTAINABLE DEVELOPMENTS IN IRONMAKING
  • 1.2.6.1. Challenges and New Developments in Blast Furnace Process
  • 1.2.6.1.1. Challenges in the Blast Furnace Process
  • 1.2.6.1.2. New Developments in Blast Furnace Ironmaking
  • 1.2.6.1.2.1. Top-Gas Recycling Blast Furnace (TGRBF).
  • 1.2.6.1.2.2. Other Possibilities to Improve Energy Efficiency and Decrease CO2 Emissions
  • 1.2.6.2. New and Alternative Ironmaking Processes
  • 1.2.6.2.1. DRI Processes
  • 1.2.6.2.2. Smelting Reduction Processes
  • 1.2.6.2.2.1. COREX Process
  • 1.2.6.2.2.2. FINEX Process
  • 1.2.6.2.2.3. HIsmelt Process [6]
  • 1.2.6.2.3. New Technological Developments in Alternative Ironmaking
  • 1.2.6.2.3.1. ULCOS: Ultra-Low Carbon Dioxide (CO2) Steelmaking (EU)
  • 1.2.6.2.3.2. COURSE50 (Japan)
  • 1.2.6.2.3.3. Hydrogen-Based Ironmaking Processes
  • 1.2.7. MODELING AND SIMULATION OF IRONMAKING PROCESSES
  • 1.2.7.1. Blast Furnace Simulation Models
  • 1.2.7.1.1. Model Categories
  • 1.2.7.1.1.1. Zero-Dimensional or Lumped Models
  • 1.2.7.1.1.2. One-Dimensional Models
  • 1.2.7.1.1.3. Two-Dimensional Models
  • 1.2.7.1.1.4. Three-Dimensional Models
  • 1.2.7.1.1.5. Discrete Element-Based Models
  • 1.2.7.2. Models of Alternative Ironmaking Concepts
  • 1.2.7.3. Summary of Ironmaking Modeling
  • REFERENCES
  • SUGGESTED READINGS
  • Chapter 1.3: The Direct Reduction of Iron
  • 1.3.1. INTRODUCTION
  • 1.3.2. RAW MATERIALS
  • 1.3.2.1. Iron Ore Deposits, Mineralogy, and Processing
  • 1.3.2.1.1. Ore Mineralogy and Deposits
  • 1.3.2.1.2. Mining and Beneficiation of Iron Ore
  • 1.3.2.1.2.1. Liberation
  • 1.3.2.1.2.2. Separation
  • 1.3.2.1.2.2.1. Flotation
  • 1.3.2.1.2.2.2. Magnetic Separation
  • 1.3.2.1.2.3. Other Technology Approaches
  • 1.3.2.1.3. Products of Physical Beneficiation
  • 1.3.2.1.3.1. Lump Ore
  • 1.3.2.1.3.2. Fine Ore or Concentrate
  • 1.3.2.1.3.3. Low-Grade Iron Ores
  • 1.3.2.2. Agglomeration of Iron Ore
  • 1.3.2.2.1. Pelletization
  • 1.3.2.2.1.1. Mixing
  • 1.3.2.2.1.2. Binders and Additives
  • 1.3.2.2.1.3. Pelletizing Technologies
  • 1.3.2.2.1.4. Pellet Induration
  • 1.3.2.2.1.5. Products
  • 1.3.2.2.1.5.1. Blast Furnace (BF) Grade.
  • 1.3.2.2.1.5.2. Direct Reduction Grade (DR Grade)
  • 1.3.2.2.1.5.3. RHF Pellets
  • 1.3.2.2.2. Briquetting
  • 1.3.2.2.3. Extrusion
  • 1.3.2.2.4. Agglomerate Characterization
  • 1.3.2.3. Reducing Agents
  • 1.3.2.3.1. Gas-Based Direct Reduction
  • 1.3.2.3.1.1. Natural Gas
  • 1.3.2.3.1.2. Syngas
  • 1.3.2.3.1.2.1. Corex Gas
  • 1.3.2.3.1.2.2. Coal Gasification Syngas
  • 1.3.2.3.1.2.3. Integrated Steel Mill Off-Gases
  • 1.3.2.3.1.3. Shaft Furnace Reducing Gas
  • 1.3.2.3.2. Coal-Based Direct Reduction
  • 1.3.2.3.2.1. Required Coal Particle Size and Chemistry
  • 1.3.2.3.2.2. Coal Physical Properties
  • 1.3.2.3.3. Other Reducing Agents
  • 1.3.2.3.3.1. Biomass
  • 1.3.2.3.3.2. Waste Organics and Char
  • 1.3.2.3.3.3. Hydrogen
  • 1.3.3. DIRECT REDUCTION PROCESSES
  • 1.3.3.1. Thermodynamics of Direct Reduction
  • 1.3.3.1.1. Reduction of Iron Oxide
  • 1.3.3.1.2. Natural Gas Reforming
  • 1.3.3.1.3. Application to Commercial DR Processes
  • 1.3.3.2. Kinetics
  • 1.3.3.2.1. Kinetics of Solid-State Reduction by CO or Hydrogen
  • 1.3.3.2.2. Kinetics of Fluidized Bed Iron Oxide Reduction
  • 1.3.3.2.3. Kinetics of Rotary Kiln Reduction
  • 1.3.3.2.4. Kinetics of Rotary Hearth Furnace Reduction
  • 1.3.3.3. Commercial Process Development
  • 1.3.3.3.1. DR Processes-History
  • 1.3.3.3.2. Gas-Based Direct Reduction
  • 1.3.3.3.2.1. Moving Bed Shaft Furnaces
  • 1.3.3.3.2.1.1. MIDREX Process
  • 1.3.3.3.2.1.2. MIDREX Process Developments
  • 1.3.3.3.2.1.3. HYL/ENERGIRON
  • 1.3.3.3.2.1.4. PERED Process
  • 1.3.3.3.2.2. Fluidized Bed Reactors
  • 1.3.3.3.2.2.1. FIOR/FINMET Processes
  • 1.3.3.3.2.2.2. Circored
  • 1.3.3.3.3. Coal-Based Direct Reduction
  • 1.3.3.3.3.1. Rotary Kilns
  • 1.3.3.3.3.1.1. SL/RN
  • 1.3.3.3.3.1.2. DRC
  • 1.3.3.3.3.1.3. Codir
  • 1.3.3.3.3.1.4. Other
  • 1.3.3.3.3.2. Rotary Hearth Furnaces
  • 1.3.3.3.3.2.1. Inmetco
  • 1.3.3.3.3.2.2. FASTMET, FASTMELT, and ITmk3.