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Ironmaking and Steelmaking

By Prof. Gour Gopal Roy   |   IIT Kharagpur
Learners enrolled: 1001
The emphasis on extractive metallurgy including ironmaking and steelmaking has been diluted significantly to accommodate newer courses on structure, properties and processing of different kinds of advanced materials. The number of faculty members in this discipline has also shrunk significantly in recent years. Ironmaking and steelmaking has been clubbed as single subject and even in some institute the subject has lost its core subject status and offered as an elective only. This is in contrary to the fact that India is going to be the second largest producer of crude steel in the world. Besides, after globalization of market, we stand in cut-through competition for day to day innovation in steel processing. Based on changing scenario a conceptual, fundamental and more quantitative course is desirable. Keeping in view of the above consideration, the course has been designed.

INTENDED AUDIENCE Metallurgy, Mechanical, Chemical
PREREQUISITES None
INDUSTRIES  SUPPORT  : HEC, Ranchi; Tata Steel, Jamshedpur; SAIL Steel plants; RINL steel Plant, JSW
Summary
Course Status : Completed
Course Type : Core
Duration : 12 weeks
Start Date : 14 Sep 2020
End Date : 04 Dec 2020
Exam Date : 20 Dec 2020 IST
Enrollment Ends : 25 Sep 2020
Category :
  • Metallurgy and Material science & Mining Engineering
Credit Points : 3
Level : Undergraduate



Course layout

Week 1:Introduction: Various routes of modern steel making (BF-BOF, DRI-EAF, SR).Blast furnace Ironmaking: Shape of the furnace, Various reactions and zones in the blast Furnace Thermodynamics of Iron making, Direct & indirect reduction .Blast Furnace as an efficient counter current gas solid reactor and maximum carbon efficiency.
Week 2:Overall heat and Material Balance in Blast Furnace.Rist Diagram based on oxygen balance,Rist Diagram based on heat & Material balance
Week 3:Blast Furnace as a two stage reactor. Predictive model for coke rate in blast furnace.
Week 4:Aerodynamics in Blast Furnace (pressure drop, fluidization, channeling, Flooding).
Week 5:Burden preparation (sintering, pelletization, coke making). Testing of raw materials
Week 6:Burden distribution in Blast Furnace.Auxiliary injection, fuel efficiency and productivity in Blast furnace.
Week 7:Thermodynamics of steelmaking. Introduction to LD steel making (process, emulsion, decarburization, catch carbon technique, impurity & slag evolution)
Week 8:Hybrid steel making. Modern EAF/IF steel making.Secondary Steel making: Thermodynamics & kinetics of deoxidation
Week 9:Secondary steel making: Vacuum treatment of steel and processes, gas stirring.
Week 10:Secondary Steel making: Ladle desulphurization, inclusion modification by calcium treatment. Inclusion control by optimizing upstream operating parameters.
Week 11:Heat transfer and segregation during casting. Ingot casting, continuous casting, defects in steel.
Week 12:Alternative routes of iron & steel making (Rotary kiln, Corex, Midrex)

Books and references

1.Ironmaking & Steelmaking: Theory & Practice, Ghosh & Chatterjee, PHI, New Delhi, 2008
2. A First Course in Iron and SteelMaking, Dipak Majumdar, UP-IIM, Hyderabad, 2015
3. Principles of Blast Furnace Ironmaking, A. K. Biswas, SBA Publication, Kolkata,1984
4.The iron blast Furnace: Theory & Practice, Peacy and Davenport, Pergamon press, Oxford, 1979

Instructor bio

Prof. Gour Gopal Roy

IIT Kharagpur
The instructor is presently professor in the Department of Metallurgical & Materials Engineering at IIT Kharagpur and also joint faculty member of Steel Technology Center and Center of Excellence on Advanced Manufacturing Technology, IIT Kharagpur. Since the inception of his professional career at IIT Kharagpur in 1997, he is teaching the course Ironmaking and Steelmaking either as separate subject courses or in combined form. His research career since inception from post graduate days has been towards the application of the fundamentals of transport phenomena in materials processing like extractive metallurgy, primarily ferrous extractive metallurgy, as well as welding. During the last 10 years his research activities has been specifically focussed to Rotary Hearth Furnace (RHF) based sponge iron technology, inclusion control in steel by upstream processing and dissimilar welding using electron beam welding. He has developed several research facilities such as electrically heated Rotary hearth Furnace, Electron beam welding set up, SEM with automated inclusion study in steel. He has two significant international collaborations:1) With Prof. T. DebRoy at Penn state university, USA and made several visit to develop an indigenous CFD code for fusion welding. 2) With Dr. Prakash Srirangam, associate Professor, WMG, UK on advanced characterization of steel inclusions, and Gleeble based simulation. He is the recipient of the Metallurgist of the Year award instituted by Ministry of Steel, GOI, in 2015 during ATM of IIM at Coimbatore. He is an editorial board member of Int. Journal STWJ. He is currently executing two large value projects 1) UAY project (MHRD-MoS-ASP,SAIL) on pilot scale RHF for sponge iron production, 7.5 cr. II) DHI satellite projects (for CoE, AMT, IIT Kharagpur_ on inclusion control in steel by upstream processing, 5.25 Cr. He is also serving as Associate Dean, Sponsored Research & Industrial Consultancy (SRIC), IIT Kharagpur.

Course certificate

•The course is free to enroll and learn from. But if you want a certificate, you have to register and write the proctored exam conducted by us in person at any of the designated exam centres.
•The exam is optional for a fee of Rs 1000/- (Rupees one thousand only).
Date and Time of Exams: 20 December 2020, Morning session 9am to 12 noon; Afternoon Session 2pm to 5pm.
•Registration url: Announcements will be made when the registration form is open for registrations.
• The online registration form has to be filled and the certification exam fee needs to be paid. More details will be made available when the exam registration form is published. If there are any changes, it will be mentioned then.
•Please check the form for more details on the cities where the exams will be held, the conditions you agree to when you fill the form etc.

CRITERIA TO GET A CERTIFICATE:
• Average assignment score = 25% of average of best 8 assignments out of the total 12 assignments given in the course.
• Exam score = 75% of the proctored certification exam score out of 100
•Final score = Average assignment score + Exam score

YOU WILL BE ELIGIBLE FOR A CERTIFICATE ONLY IF AVERAGE ASSIGNMENT SCORE >=10/25 AND EXAM SCORE >= 30/75.
•If one of the 2 criteria is not met, you will not get the certificate even if the Final score >= 40/100.
• Certificate will have your name, photograph and the score in the final exam with the breakup.It will have the logos of NPTEL and IIT Kharagpur. It will be e-verifiable at nptel.ac.in/noc
•Only the e-certificate will be made available. Hard copies will not be dispatched.


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