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.
