Iron Making Projects

Benification
Benification is the first step to iron making whereby extracted ore from mining is reduced to particles that can be separated into mineral and waste, the former suitable for further processing or direct use. It involves concentrating the mineral content of an ore by ore-dressing, smelting and pelletizing. The process usually takes place close to the site of an ore body prior to its transportation to a manufacturing area.

Treatment of raw material (such as pulverized ore) is done to improve physical and chemical properties in preparation for further processing. The technique of benification includes washing, sizing of particulates and concentration (which involves the separation of valuable minerals from the other raw materials collected from a grinding mill). In large-scale operations, various distinguishing properties of the minerals to be separated (e.g., magnetism, wettability, density) are exploited for assimilating the desirable components.

Pelletizing
Pelletizing is the process of molding or compressing products into shape of pellets. The objective is to produce pellets in an appropriate band of sizes and with mechanical properties high enough to maintain its usefulness during the stresses of transference, transport, and use. Both mechanical force and thermal processes are employed to produce the desirable pellet properties. Generally, there are two alternatives available for industrial production of iron ore pellets; drum and pelletizing disk.

In order to achieve high resistance metallurgic mechanics and appropriate characteristics, the pellets are subjected to thermal processing, which involves stages of drying, daily pay burn, burn, after-burn and cooling (in a cooling tower). The duration of each stage and the temperature that the pellets are subjected strongly influence the final product quality.

Sintering
The process of sintering involves the heating of fine iron ore with flux and coke fines or coal to produce a semi-molten mass that solidifies into porous pieces of sinter with the size and strength characteristics necessary for feeding into the blast furnace. Raw material for making of iron is obtained by this process.

Blast Furnace
Blast furnace is used to chemically reduce and physically convert iron oxides into liquid iron called "hot metal". The metallurgical furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are charges into the top, and preheated air is blown into the bottom. The raw materials require 6 to 8 hours to descend to the bottom of the furnace where they become the final product of liquid iron and liquid slag. These liquid products are drained at regular intervals from the bottom of the furnace. The hot air that was blown into the bottom of the furnace ascends to the top within 6 to 8 seconds after going through numerous chemical reactions. Once a blast furnace is started it can continuously run for four to ten years with only short stops to perform planned maintenance.

Mini Blast Furnace
We can efficiently execute wide range size MBF project from small iron making furnace to medium on turnkey basis. The blast furnace can be made available in different capacities like 35M3, 65M3, 128M3, 158M3 and 230M3 . Daily pig iron production is from 100-700 tons. The blast furnace will be designed for high practicality, excellent performance, low investment and easy maintenances.

In this stage, impurities such as phosphorus, sulfur, and excess carbon are removed from the raw iron, and alloying elements such as nickel, manganese, chromium and vanadium are added to produce the specific grade of steel.

The modern Steelmaking processes is broadly classified into two categories: primary and secondary steelmaking. Primary steelmaking process uses new iron as the feedstock, usually from a blast furnace. Secondary steelmaking uses scrap steel as the raw material.

EAF (Electric Arc Furnace)
The electric arc furnace offers an alternative method for production of bulk steel. Unlike the basic oxygen route, this furnace does not use hot metal. It is charged with "cold" material which is manly steel scrap - which could have been otherwise environmentally damaging. Various other forms of raw material are also available.

Steel scrap is first tipped into the electric arc furnace using an overhead crane. A lid is then carefully swung into position over the electric arc furnace. This lid comprises of three graphite electrodes which are lowered into the electric arc furnace. Electric current is passed through the electrodes which forms an arc. The heat generated by this arc melts the steel scrap.

During the melting process, other metals (ferro-alloys) are added to the steel to achieve the desired chemical composition. Also oxygen is blown in to the electric arc furnace for purifying the steel.

After samples have been collected to check the chemical composition of the steel, the electric arc furnace is tilted to allow the slag, which is floating on the surface of the molten steel, to be poured off. The electric arc furnace is then tilted in the other direction and the molten steel is poured into a ladle, where it furthered for secondary steelmaking process or is transported to the caster.

BOF (Basic Oxygen Furnace)
This process of steelmaking involves the chemical reduction of iron ore, using an integrated steel manufacturing process or a direct reduction process. In the conventional method of steel manufacturing , the iron in blast furnace is converted into steel in a basic oxygen furnace (BOF). Basic oxygen furnace are typically employed for high-tonnage production of carbon steels.

In the BOF process, the preliminary stages of steelmaking include coke making and iron making. Pig iron is manufactured from sintered, pelletized, or lump iron ores using limestone and coke in a blast furnace. It is then fed to a BOF in the form of molten slag along with scrap metal, fluxes, alloys, and high-purity oxygen to produce steel. In some integrated steel mills, sintering (heating without melting) is used to agglomerate fines and so recycle iron-rich material like mill scale.

Vaccum Degaser
Vaccum degassers are high efficiency inline modules that are basically used to remove the dissolved gases. These degasser can be horizontal, vertical or round vessel. High pressure vacuum pressure is created to pull in the gas cut mud. When the liquid enters the tank it will flow and be distributed to a layer of internal baffle plates designed for the mud to flow in thin laminar film. The surface is exposed to a vacuum that forces the gas to escape and break out of the mud. The vacuum pump propels the escaping gas from the vessel discharging it to the rig's flare or environmental control system. Sonication and stirring under reduced pressure usually enhances the efficiency of the degassing process. This technique is commonly known as Vacuum degasification. Specialized vacuum chambers, called vacuum degassers, are used to degas materials through pressure reduction. It is commonly used in the process of steelmaking.

Continious Caster
Continuous Casting Machine (CCM) is revolutionary process equipment used for continuous production of slabs in a single operation. The continuous casting process dramatically boosts productivity and saves significant amount of energy by eliminating the need for a soaking furnace.

The integrated machine can be used to produce slabs, blooms, and billets by continuously pouring molten steel produced by the converter or electric furnace into a mold. Slabs are used as the material for rolling. We specialize in providing a full range of solutions for CCM (Continuous Casting Machines).

Rolling Mill
Rolling mill forms an integral part of various factories in metalworking industry. It is basically used for shaping metal by passing it between a pair of work rolls. Rolling mills are often incorporated into integrated steelworks, but also exist as separate plant. This type of mills can be used for other metals, and different materials.