Unit 1 Introduction to Ironmaking

4 lecture hours

• Introduction to the ferrous extraction process. 1.2
• Importance of iron in the engineering field. 1.3
• History of ancient Indian Ironmaking 1.4
• Modern ironmaking practices. 1.5
• Products of ironmaking: Wrought iron and pig iron

Unit 2 Raw materials of iron making

7 lecture hours

• 2.1 Raw materials used for Iron making: (a) Iron ore – types
• Valuation of ore
• (b) Metallurgical coke – functions
• (c) Fluxes – importance and types
• (d) Air 2.2 Issues of Indian’s raw materials 2.3 Beneficiation of iron ore – Crushing
• screening and magnetic separation 2.4 Agglomeration processes – Sintering
• Nodulizing 2.5 Testing methods for agglomerates – Drop test
• Compression strength
• Shatter index
• Tumbler index
• Reducibility test

Unit 3 Blast Furnace process

14 lecture hours

• Plant layout and constructional features of blast furnace (BF) 3.2
• Temperature profile of BF 3.3
• Refractories used in BF 3.4
• Physical and chemical properties of charging (or burden) materials 3.5
• Charging systems of BF – Two bell and Bell-less top 3.6
• Reactions involved in each zone of BF
• Direct and indirect reduction
• Concept of Tuyere Flame Temperature (TFT) and Raceway Adiabatic Flame Temperature (RAFT) 3.8
• Characteristics of pig iron and slag
• Basicity and V ratio of slag 3.9
• Desulpurization of hot metal 3.10
• Modern trends of BF practice

Unit 4 Blast furnace auxiliaries and operations

• Cleaning of BF gas – Dust catcher
• Primary and secondary 7 15 Program Name: Diploma Engineering Level: Diploma Branch: Metallurgy Engineering Subject Code: DI04021041 Subject Name : Iron Making cleaning system 4.2
• Hot blast stoves 4.3
• BF cooling arrangements 4.4
• Operations of BF and irregularities in operations

Unit 5 Alternative methods of iron making

9 lecture hours

• Alternative methods of Iron making - Needs
• advantages, and limitations 5.2
• Raw materials and their characteristics – iron ore, non-coking coal
• natural gas, flux 5.3
• Direct reduced iron or Sponge iron processes: Merits
• demerits, and types : (a) Coal-based – Rotary kiln and Rotary hearth
• (b) Gas-based – Midrex and HyL 5.4
• Characteristics and use of sponge iron 5.5
• Smelting Reduction process: Corex process 5.6
• Mini-blast furnace

Unit 6 Sustainable development in iron making plant

4 lecture hours

• Pollution control – Processing of steel plant waste materials and utilization
• CO2 emission
• Energy conservation practices in the plant 6.3
• Green technologies for iron making