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Course Outline

 

Understanding the Building Blocks

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Introduction & overview

 
  • Examine samples of the raw materials and in-process products
  • overview a steelworks site identifying the key components
  • introduce the major jargon – incl. semi-finished and finished products
   
 

Iron ore fundamentals

 
  • Geology
  • Types
  • Deposit locations
  • Products
   
 

Sintering

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Pelletising

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Coal fundamentals

 
  • Geology
  • Types
  • Deposit locations
  • Products
   
 

Coal preparation

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Coke-making

 
  • Process flowsheet description
  • Key operational characteristics
  • By-product versus non-recovery batteries
   
 

Blast furnace ironmaking

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Oxygen steelmaking

 
  • Process flowsheet description
  • Key operational characteristics
  • Hot metal pre-treatment
   
 

Electric steelmaking & stainless steel

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Ladle refining & vacuum degassing

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Forming, rolling & coating

 
  • Process flowsheet description
  • Key operational characteristics
   
 

Putting the Building Blocks Together

 

Raw material trade & materials handling

 
  • Iron ore and coal trade flows
  • Shipping
  • Stockpiles
   
 

Measures & process implications of iron ore quality

 
  • Chemical analysis
  • Physical properties
  • Lump versus fine ore
  • Mineralogy
   
 

Measures & process implications of coal quality

 
  • Proximate analysis
  • Physical properties
  • Carbonisation properties
  • Caking and non-caking coals
  • Petrographic analysis
   
 

Measures & process implications of sinter, pellet & coke quality

 
  • Chemical analysis
  • Physical analysis
  • Cold strength tests
  • Hot strength tests
   
 

Process implications on blast furnace operations & hot metal quality

 
  • Impact of sinter and pellet quality on blast furnace operation
  • Impact of coke quality on blast furnace operation
  • Blast furnace operation with pulverised coal injection (PCI)
  • Hot metal pre-treatment
   
 

Implications of steel product requirements

 
  • Impact of steel grade on steelmaking operations
  • Impact of steel product type on post steelmaking treatment
   
 

Slags

 
  • Blast furnace slag
  • Steelmaking slags
  • Utilisation of slags
   
 

Refractories, energy & in-plant transportation

 
  • What are refractories and where are they used
  • Overview of the steelworks energy balance
  • Torpedo and other ladles
   
 

Steel trade & other marketing issues

 
  • The market for semi-finished steel products
  • Long products versus flat products
   
 

Plant layout & location issues

 
  • Product flow within the steel plant
  • Coastal versus inland sites
  • Strategic advantage in location – proximity to raw materials, market etc.
   
 

Recent trends & possible future process developments

 
  • Alternative cokemaking processes
  • Alternative ironmaking processes
  • Steelmaking practice innovations in Asia
   
 

Conclusion & review

   
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