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Metal Manufacturing Processes and Energy Systems
Published in Swapan Kumar Dutta, Jitendra Saxena, Binoy Krishna Choudhury, Energy Efficiency and Conservation in Metal Industries, 2023
Swapan Kumar Dutta, Binoy Krishna Choudhury
Pig iron can contain 3.5–4.5% carbon, with sulfur less than 0.05%. It is an intermediate product to produce other forms of useful iron such as cast iron and steel. Pig iron is mostly produced in blast furnaces and mini-blast furnaces, and it is further processed in basic oxygen furnaces (BOFs), electric arc furnaces (EAFs), cupola furnaces, etc.
Design in structural steelwork to EN 1993 and EN 1994
Published in Chanakya Arya, Design of Structural Elements, 2022
Cast iron is basically remelted pig iron which has been cast into definite useful shapes. Charcoal was used for smelting iron but in 1740 Abraham Darby found a way of converting coal into coke which revolutionised the iron-making process. A later development to this process was the use of limestone to combine with the impurities in the ore and coke and form a slag which could be run off independently of the iron. Nevertheless, the pig iron contained many impurities which made the material brittle and weak in tension.
Materials Engineering
Published in Quamrul H. Mazumder, Introduction to Engineering, 2018
The iron coming from a blast furnace is known as pig iron because hundreds of years ago, blast furnace iron was fed into ingots whose shapes reminded the workers of piglets. Pig iron has high carbon levels, up to 4%; this makes pig iron too brittle for many uses.
Steady-State Heat Flux Prediction to Slabs in a Walking Beam Furnace
Published in Heat Transfer Engineering, 2023
Zaaquib Yunus Ahmed, Ilya T’Jollyn, Steven Lecompte, Toon Demeester, Teun De Raad, Michel De Paepe
The process of steel production starts with the reduction of iron ore to pig iron in the blast furnace. The pig iron is then processed in the converter to obtain liquid steel which is cast into slabs or billets. ArcelorMittal Gent produces flat steel; hence we will focus our discussion on the production of steel slabs. The cast slabs are stored in a slab yard until that specific grade of steel needs to be rolled into sheets. During its residence in the slab yard the slab cools down. In order to be suitable for rolling, the slab core temperature is preferred to be about 1200 °C, in order to protect the rollers from excessive stresses during the rolling operation. This is achieved using a reheat furnace fitted with burners, which burn natural gas (NG) or in-house produced coke oven gas (COG). The slabs are transported through the different zones in the furnace with the help of walking beams (skids).
An integrated batching problem for steel plate manufacturing with bi-strand casting
Published in International Journal of Production Research, 2023
Myungho Lee, Juntaek Hong, Hyunjoon Kim, Inhye Bang, Kangbok Lee, Byung-In Kim, Jungkyu Kim
The steel plate manufacturing process consists of iron-making, steel-making, continuous casting, rolling, and shearing. See Song (2009) and Song (2014). In the iron-making stage, iron ore is melted with cokes to make pig iron, which is iron with impurities. The steel-making stage is to purify pig iron to make steel with a steel grade, a chemical composition of steel ingredients, such as carbon, manganese, etc. The continuous casting stage is to make slabs (brick-shaped intermediate goods) with molten steel. In the rolling stage, slabs are pressed by a roller to become mother plates, and in the shearing stage, mother plates are cut into plates, which are the final products. Due to the process industry's characteristics, manufacturing operations are often processed in batch, and each operation has its own batching condition and criteria. The batching problems for steel-making and continuous casting (SCC) in the steel industry have been studied for more than two decades, since they are closely knitted and profoundly affect the steel industry's productivity. See Tang, Wang, and Chen (2014) and Tang et al. (2011).
VOC and PAH characterization of petroleum coke at maximum thermal decomposition temperature
Published in Energy Sources, Part A: Recovery, Utilization, and Environmental Effects, 2019
Didem N. Inceoğlu, İsmail Özbay, Aykan Karademir
Hard coal has a great importance in iron and steel works. Integrated steel plants produce pig iron in the blast furnace. Reduction of iron ore in blast furnace can be actualized in the presence of metallurgical coke. The quality of metallurgical coke is based on the quality of the used hard coal and production parameters in coke ovens. Since the production cost and released emissions are a great concern, coal blends are prepared by using different coal types and additives to optimize the cost and quality parameters (not only coke quality but emission parameters as well). One of the widely used blend additives is petcoke (Inceoglu and Durmusoglu 2014). Petcoke contains high carbon and low ash qualities, but often with an undesirably high sulfur content (Zhong et al. 2018a). Three main types of petcoke which are called needle coke, shot coke, and sponge coke, are the products of different petroleum residual pyrolysis processes (Escallon 2008). Sponge coke with more complex structure has a higher yield and widest range of applications (Zhong et al. 2018b). The physical properties and the types are changed accordingly. In coke production process, shot coke and sponge coke are preferred as the additives to reduce the blending costs. Sponge coke’s physical appearance is a sponge-like porous and continuum structure and defined as intermediate type (Ibrahim 2005). This property makes it more preferable in coke production process.