LONG ANSWER QUESTIONS

Unit V
Q) 1. Draw neat sketch of blast furnace and label all parts?

A]

2Q] Explain the process of production of pig iron?

A] The blast furnace is charged with iron ore coke and limestone at the top by using a special
skip car. the hot air blast at a temperature of about 550 to 750 degree Celsius is supplied through
tuyeres located just above the hearth level.
The amount of each charging material depends on the operational conditions. under Indian
conditions 1.75 tonnes of ore 0.8 to 0.9 tonnes of coke and 0.5 tons of limestone are required to
make 1 ton of pig iron.iron ore is the iron bearing mineral and from the iron ore pig iron is
produced by reducing the oxygen the Coke is for reduction of the iron ore and for heating.the
limestone combines with the gangue of the ore and with the ash of the Coke so they can be
removed as a low melting slag. the air supply the oxygen for combustion of Coke as well as
promoting the chemical reduction of iron oxide.

The carbon combines with the oxygen to form carbon dioxide but carbon dioxide immediately
combines with more carbon to form carbon monoxide according to the reaction,

CO2 + C = 2CO

The hot gases rich in carbon monoxide password through the Furnace and heat the descending
charge. In the upper part of the Furnace iron ore is reduced by carbon monoxide according to the
reaction,

FE2O3 + 3CO = 2FE+3 CO2

At the middle of the stack, decomposition of limestone into lime takes place according to the
reaction,

CaCO3 = CaO + CO2

As charge descents, reduction of other oxides takes place according to the reactions,

MnO + C = Mn + CO

SiO2 + 2C = Si + 2CO

P2O5 + 5C = 2P + 5CO

Melting of slag and metal commences in the bosh. By the time charge descends into the lower
portion of the bosh, that is just above the tuyeres level, everything else except coke is Molten. the
elements liberated are dissolved in the molten metal. Carbon is dissolved in both solid and liquid
iron.

The sulphur released from the charge is remained in the molten iron in the form of ferric
sulphide. its removal need a basic slag rich in lime as well as a high hearth temperature sulphur
is removed from the melt according to the following reaction,

FeS + CaO +C = Fe + CaS + CO

And as a result of it part of sulphur goes into the slag in the form of calcium sulphide which is
insoluble in metal.
Finally molten slag and metal collect in the hearth. the slag floats on the surface of the heavier
metal and is tapped off from the Furnace through the slag hole. when sufficient molten iron has
gathered in the heart it can be drawn off and cast into bars called pigs. generally molten iron is
tapped for every 6 hours through a tapping hole

3Q] Explain the production of cast iron using cupola furnace?

A] Production of pig iron in blast furnace is the first stage of producing cast iron and steel. Pig
iron is refined in cupola furnace to obtain cast iron. Cupola is similar to blast furnace, but is
smaller in size and does not work continuously as blast furnace. It consists of cylindrical shell
lined with fire bricks. The diameter of cupola varies 0.9 to 2 m with the height of from 4 to 5
times the diameter. The provision is made to introduce air blast and two notches to remove the
slag and molten cast iron
Before starting, cupola is prepared which includes repairs of lining.A layer of 100 to 150 mm
thick sand is rammed on bottom with a slope towards the tapping hole. This facilitates easy flow
of molten metal. Soft and dry pieces of wood are placed on the sand bed and then Coke is
charged on the bed, extending about 0.75 metres above the tuyeres.

To start the cupola, Coke is first lit at the bottom. When this properly established, the Cupola is
charged from the charging door. the charge consisting of metal, coke and limestone is dropped in
alternate layers on the burning Coke bed. The charge is extended up to the bottom level of
charging door before the blast is put on.

When the Furnace is started air blast enters the furnace through tuyeres. The limestone melts and
forms a flux which protects the metal against excessive oxidation. the hot gases rise to the
Furnace and melt the iron. The atmosphere in the coupler is slightly oxidizing. it does not permit
much control of metal composition. Phosphorus content remains unchanged. sulphur is
undesirable impurity in iron. Sulphur present in the Coke increases the sulphur content in the
iron

Molten iron becomes available in less than 15 minutes after the air is put on. being heavier it
falls to the base of furnace leaving slag floating on its surface the slab and the molten iron are
removed from separate notches. molten iron is tapped off into ladle and cast directly into mould

4Q) Explain steel making process using Bessemer converter?

ANS : THE BESSEMER CONVERTER PROCESS

The molten pig iron low in Sulphor and phosphorous is charged into the converter from the top.
A stream of air is forced through the molten pig iron to oxidize the impurities.

For the Bessemer process no external source of heat is needed, since the oxidation of silicon,
manganese and carbon of the pig iron liberates enough heat for the process. The flow of air is
continued for about 15 minutes, and the oxidizing sequence can be followed by the following by
the characteristics of the blast oxidizes the iron to ferrous oxide .

2 Fe + O2 = 2 FeO

this iron oxide then reacts with the impurities . The elements silicon, manganese and carbon are
eliminated in the order indicated below.

Si + 2 FeO = 2Fe + SiO2

Mn + FeO = Fe + MnO
 C + FeO = Fe + MnO

c+ FeO = Fe + CO

The oxidation of these impurities provides the necessary heat for the process. The carbon escapes
as gas, whilst silicon and manganese along with any iron that may be oxidized removed as slag .

The composition is finally adjusted by adding ferro manganese and ferro silicon, and the steel is
poured into a ladle; and then teemed into moulds. The converter capacity is about 25 to 60
tonnes, and the process takes about 25 minutes.

The Bessemer converter in three position s- charging blowing and pouring during charging the
converted is in horizontal position and molten pig iron is poured

Phosphorus is removed as per the following reactions.

2p + 5 FeO + 4 CaO = (CaO)4 p2 O5 + 5 Fe

(phosphorus) (iron oxide) (lime) (calcium phosphate (slag)) iron

Sulphur is removed during the below and passes into the slag as a calcium sulphide and
manganese sulphide .

FeS + Mn = Fe + MnS (mangansese sulphide )

FeS + CaO = FeO + CaS (calcium sulphide)

During the after blow there is no flame is no to indicate to the operator the exact point of the
elimination of phosphorus . He is guided by experienced only . After the blow the converter will
contain highly basic slag.
 The slag is poured off into the slag ladle before adding deoxidizers and recarburiser to the
steel . These are added in the same manner as in the acid process.

Use of basic Bessemer steel :

a large % of this steel is normally used for tube manufactured ,.but due to high nitrogen content
the steel is not suitable for deep drawing purpose this is a common feature of both acid and
basic Bessemer steels.

5 Q Explain the method of production of steel by electric furnace?

Ans: Electric furnace

In electrical process the use of electrical heating permits better control of composition and
temperature of metal bath. Because of high cost of electrical energy, their use is restricted for
high quality steels and high alloy steels. The electric process may be carried out in electric
furnaces induction furnaces.

Electric arc furnace:

1. It is lined with suitable refractory materials. The electric current is delivered into the
furnace through graphite or carbon electrodes which are controlled automatically during
charging and melting.
2. The electric furnance may be used for acid or basic methods of steel making. However
the basic furnace has a very limited application and are mainly used in steel foundries.
3. In basic arc process, the selected scrap is carefully charged into the furnace through the
charging door. The current is turned on, the electrodes are lowered until an arc is struck
between the electrodes and the charge. Some iron (or milli scale) and lime are fed, and
slag retains these oxides. The slag holding these oxides is removed and basic reducing to
control fluidity of the slag will also contain fluidity of the slag. This slag will also contain
calcium carbide because of the interactions of the lime and carbon at furnace temperature
CaO + 3C = CaC2 + CO
(lime ) carbon (calciucarbide ) (carbon monoxide)

The main function of this slag

(carbide slag ) is to remove
sulpur and further reduction of
iron oxide . The analysis of slag
and bath have been adjusted to
proper furnace is titled for
tapping so that molten metal
steel is removed first. Slag cover the steel and protected it until all the steel is removed and
care must be exercised to prevent the slag from entering the metal .

The main product of the basic electric arc furnace are special alloy steels, high
carbon steels, special tool steel and high –speed steels.

6. Q. Expalin the effects of varoius alloying elements on properties of steel.

Ans : Effects of alloying elements :

The alloying elements are deliberately added to steel in order to modify its properties. The
effects of main alloying elemnts on the properties of steels are considered below.

Aluminium: Aluminium is added for deoxidation of molten steel, and thus prevents blow holes
and casting defects. Presence of aluminium in the steel aid nitriding because of its high affinity
to nitrogen.

Boron : Boron is added in small quantities to improves hardenability of steels.

Chromium: chromium as an alloying element imparts many useful charecterstics.

It improves hardness and tensile stength. Chromium is mostly used with other alloying elements
such as nickel , molybdenum and vanadium. Chromium is mainly added to improves corroison
and wear resistance of steels.

Cobalt : cobalt in combination with tungsten or molybdenum imparts red hardness to high speed
steels i.e , retain high strenth and hardness at elevated temperature .

Copper : copper increases resistance to corrosion . It also gives greater fluidity to the molten
metal for castings.

Manganese : addition of maganese into steel greatly increases its strength,hardness and
toughnsss .

Molybdenum : molybdeneum increase strength hardness and toughness of steel . It also

promotes grain refinement , increase hardenabilty and imparts red hardness in steels.

Nickel : nickel increases strength and hardness without affecting ductility of steel. Nickel
incombination with chromium improves corroison and wear resistance . It also improves heat
resistant.

Silicon : silicon acts as a deoxidediser . It increases strength and hardnes s.

Sulphur : sulphur is addes to improves chip formation , thus improves machanability.

Tungsten : tungsten as an alloying element improve s hardnes and toughness of the and
hardness at elevated temperature (at red heat ).
Vanadium : vanadium increase hardnesss and toughness of the steel . When alloyed with
chromium , vanadium improves resistance to shock and fatigue .

Effects of alloying elements on the properties of steel are summarized below (table 5.3).