Iron melting process pdf

Metal casting enables the production of simple to complex parts that meet a variety of needs. The molten metal is transferred to the pouring area where the moulds are filled. Control of slag and insoluble buildup in ladles, melting and. The ore part of a charge consists of iron ores and concentrates, manganese ores and various types of scrap containing iron. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. It may take place at different process in com bination or separately. It was stated that ferrosilicon can be replaced by silicon carbide during the synthetic cast iron melting process. Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. The portion on top is the nickeltoaluminum or irontoaluminum ratio that will yield the maximum exotherm. It is possible to use lower grade scrap which contains residual elements, if this scrap is blended with clean iron units so that the resulting residual levels in the steel following melting meet the requirements for the specific steel grade. Many of the impurities associated with iron ore are difficult to melt, and so they will not form a proper slag easily, which retards the smelting process.

Proper use of the exotherm is made in the melting of nickel and iron aluminides by using the furnaceloading scheme shown in figure 2. A blast furnace charge consists of ore, fluxes and fuel. Cleaning cleaning involves removal of sand, scale, and excess metal from the casting. The melting, holding and pouring process energy and.

Sintering is a thermal agglomeration process that is applied to a mixture of iron ore fines, recycled ironmaking products, fluxes, slagforming agents and solid fuel coke. Production of gray iron castings asm international. The bos process uses pure oxygen, injected by a lance, for refining the. Iron ore processing for the blast furnace courtesy of the national steel pellet company the following describes operations at the national steel pellet company, an iron ore mining and processing facility located on the mesabi iron range of minnesota. Overview of cast iron melting and pouring processes. Methodology of fault diagnosis in ductile iron melting process.

Inoculation is a procedure whereby the microstructure and properties of cast iron are controlled. Production of pig iron in a blast furnace 9 scheme of a blast furnace content. Creating steel from lowgrade iron ore requires a long process of mining, crushing. It melts about 200kgs per hour but i ran it mostly 40 mins at a time because of the time needed to. Pdf melting of grey cast iron based on steel scrap using silicon. Melting and pouring the preparation of molten metal for casting is referred to simply as melting. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom hotrolled and coldrolled strip coils structural shapes. The composition of slag varies with the type of melting process used and the type of iron or steel being melted. The proposed methodology was tested using real foundry data set containing 1020 records with contents of 9 chemical elements in the iron as the process input variables and the ductile iron grade. Amazing cast aluminum process using sand mold, fast melting metal casting technology working. This is the traditional raw material for iron melting but, again, avail. The most widely used method for small to mediumsized castings is green sand molding. The process consists of pouring molten metal into a mold containing a cavity of the desired shape.