Ferrous Extraction Metallurgy

At the end of this course, students should be able to: 1. grasp the thermodynamics of iron reduction based on Ellingham diagram; 2. explain the concepts of desulphurization and deoxidation; 3. describe the technology involved in the refining processes; 4. develop local raw materials for use as inputs in direct and indirect iron and steel making; and 5. describe the technology of ferroalloys production.

Ironmaking: Review of raw materials for ironmaking. Iron Blast Furnace - Design, reactions and process control. Post-production treatment of the products of the Iron Blast Furnace - Slag granulation and uses, gas cleaning, flue dust removal and hot metal treatment e.g., desulphurisation, dephosphorisation and desiliconisation; Direct reduction - Process description, reactions and products, process control. Steelmaking: Review of raw materials for steelmaking. Basic Oxygen Steelmaking - Design of the converter, physico-chemical reactions, process and quality control. Electric Arc Steelmaking - Reactor design, continuous feeding, power programme, process and quality control. Alloy steel production e.g., stainless steelmaking - process and quality control; AOD. Secondary Steelmaking: Clean steel production processes e.g., vacuum induction melting, electroslag remelting, degassers. Other secondary steelmaking processes e.g., calcium treatment and steel desulphurisation. Stirring and injection techniques. Deoxidation of steel: Thermodynamic principles and methods. Pre- requisite: MAE 301.