The course provides a detailed analysis of the theoretical and technological aspects of
the production of sponge iron and cast iron from the respective raw materials as well
as the theory and technologies used for the production of steel and iron alloys.
In the theoretical part of the course, the properties of raw materials and auxiliary
materials, the physicochemistry of the iron reduction process, the factors that affect
the reduction kinetics of iron oxides as well as the technology of ferrous products
production are discussed. Emphasis is placed on the main metallurgical processes,
fossil fuels/reducing agents (solids and gases) properties as well as their
modifications for the production of reducing gases. The composition and properties
of the metallurgical slags of various compositions and origin as well as the chemical
equilibrium between slag and metal phases are discussed in detail. The main
chemical reactions that take place in the stages of steel purification are also
discussed.
The technological part of the course includes the methods of direct reduction of iron
ores and their technological development for the production of sponge iron in shaft
and rotary kilns. The technology of gasification of solid fuels and production of
reducing agents from hydrocarbons by methods of catalytic conversion or partial
oxidation in order to be used in reductive roasting plants is presented. The methods
of reductive melting for cast iron production in blast furnaces from iron ores and
smelting of scrap iron in electric arc furnaces for the production of molten iron are
also examined in detail. Refining methods in AOD and VOD furnaces as well as in
ladle furnaces and their technological developments are presented. The technology
for the production, refining and regulation of steel quality is analyzed. Essential
aspects of the whole process such as electrode and refractory consumption and
energy consumption are discussed. The operation of the electric arc furnace is
analyzed and the formation and operation of the Soderberg electrodes are described.
The technology of production of ferro-alloys (FeSi, FeMn, FeNi, FeCr) and stainless
steel is also described.
- Teacher: Άνθιμος Ξενίδης
- Teacher: Ειρήνη Χριστοδούλου
ECTS : 5
Language : el, en
Learning Outcomes : Upon completion of the course, the student will: • Have understood the basic characteristics of iron ores, reducing agents and fuels, steel and ferroalloys. • Know the metallurgical furnaces used for the reduction of iron ores and for steelmaking, their characteristics, advantages and disadvantages. • Propose suitable pyrometallurgical methods for the production of sponge iron, pig iron, steel and ferroalloys. • Calculate the degree of oxidation and reduction of iron ores. • Perform calculations of mass and energy balances, enthalpy change, and control the factors that determine the rate of iron oxide reduction. • Perform calculations to find the melting point of produced slag using a triangular diagram and the required amount of flux so that the produced slag has specific desired properties. • Be able to investigate whether iron ore reduction methods are economic and efficient.