PROIZVODNJA ČELIKA PART 5
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- Mariah Wilkins
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1 ..: Proizvodnja gvožďa i čelika..: Rude željeza..: Proizvodnja sirovog željeza, Visoka peć..: Hemijski procesi kod proizvodnje čelika..: Postupci kod proizvodnje čelika..: Bessemer, : BOH, : EAF, : BOF, : Dijagram toka proizvodnje sirovog čelika..: Dijagram toka proizvodnje čeličnih proizvoda PART 5 PROIZVODNJA ČELIKA strana 1 Srednja mašinska Srednja škola, mašinska Novi škola, Sad, Srbija Novi Sad, Srbija
2 Željezna ruda Proizvodnja gvožďa i čelika Visoka peć Sirovo željezo Pudlovana peć Bessemer konverter Peć sa otvorenim ložištem Elektro peć Basic Oxygen Process Kupolna peć Pudlovano gvožďe (varen čelik) Dobijen na temperaturi ispod tačke topljenja Čelik Liveno gvožďe strana 2
3 Proizvodnja gvožďa i čelika Sirovina željezna ruda Magnetit Fe 3 O %Fe Hematit Fe 2 O %Fe Limonit Fe 2 O 3 3H 2 O %Fe Siderit FeCO %Fe strana 3
4 Proizvodnja gvožďa i čelika 2C + O 2 2CO Fe 2 O 3 + 3CO 2Fe + 3CO 2 Visoka peć Procesi visoke peći Redukcija rude Ugljenisanje željeza Sirovine Željezna ruda Krečnjak..: Uz dodatke, od jalovine rude i pepela koksa stvara lakotopljivu šljaku Koks..: Gorivo..: Reduktivno sredstvo (vezuje kiseonik)..: Sredstvo za ugljenisanje željeza Drugi dodaci strana 4
5 Proizvodnja gvožďa i čelika Sirovo željezo Hemijski sastav Primer dnevne proizvodnje 1.000t koks 3.000t ruda i krečnjak 3.600t toplog vazduha 3 4 %C %Mn %P ispod 1.0 %S 1 3 %Si ostalo %Fe 1.200t sirovog željeza 800t šljake 5.000t otpadnog gasa Klase sirovog željeza Dnevna proizvodnja dostiže t Osnovno (belo)..: za dalju proizvodnju čelika..: 1.5 max %Si..: 0.04 max %S..: C hemijski vezan u cementit Fe 3 C Livačko (sivo)..: za dalju proizvodnju livenog gvožďa..: jedan %C izdvojen iz željeznog karbida Ferolegura..: kao aditivi u proizvodnji gvožďa i čelika..: npr. feromangan i ferosilicijum strana 5
6 Mn + FeO MnO + Fe Si + 2FeO SiO 2 + 2Fe FeS + CaO CaS + FeO FeO + Mn MnO + Fe Hemijski procesi Proces oksidacije primesa Vazduhom Željeznim oksidom Čistim kiseonikom FeO Proces dezoksidacije oksida feromangan ferosilicijum aluminijum gas šljaka umireni čelici CO MnO neumireni čelici legiranje ugljenisanje SiO 2 CaS P 2 O 5 Obloga peći Bazna dolomit CaCO 3 MgCO 3 magnezit MgCO 3 Kisela siliko opeka strana 6
7 Postupci Belo sirovo željezo i čelični otpaci Bessemer Process 1856 Siemens Martin Process, BOH 1867 Electric Arc Proces, EAF 1907 Basic Oxygen Process, BOF 1952 strana 7
8 Bessemer process "The Manufacture of Iron Without Fuel 24 August Prvi znatno jeftiniji proces Oko 15t po šarži Otvorena čelična posuda Perforirano dno tzv. tuyères za dovod vazduha Proces oksidacije Si i Mn konvertuje u šljaku Gašeni kreč uklanja P US stop Henry Bessemer Bessemer converter, Kelham Island Museum, Sheffield, England (2010) strana 8
9 Siemens Martin process Open hearth furnace Siemens ova regenerativna peć, 1850 ih koristi opeku i otpadne gasove 60 70% uštede goriva Martin prvi primenjuje peć Brza proizvodnja, veće količine Kapaciteti t po šarži Lakše kontrolisan proces Koristi i otpadni čelik, reciklaža Smanjeni troškovi proizvodnje Vrlo brzo je potisnuo Bessemer ov proces 1950 tih gašenje peći u zap. Evropi Danas 1/6 čelika ovim postupkom (Ukrajina, Indija, Rusija) strana 9
10 Electric Arc Process EAF Električni luk, AC, grafitne elektrode US, prva EAF Tokom II sv. rata samo za legirane čelike Nakon ekspanzija Kapacitet od 1 400t Transformatori do 300MVA, 900V, 44kA 1t..: 440kWh 300t..: 300MVA, 132MWh ~ 37 min. Ekonomski opravdan samo ako..: postoji dovoljno energije..: dobro razvijena električna mreža Može se 100% reciklirati otpadni čelik Fleksibilnost (ON OFF) DC, plazma luk, vakuum luk strana 10
11 Oxygen Processes BOS, BOP, BOF, OSM, Linz-Donawitz-Verfahren, LD converter, Oxygen Converter Process Razvijen LD, Austrija Poboljšan Bessemer ov postupak vazduh kiseonik Vrlo efikasan proces Nekoristi dodatno gorivo oksidacija nečistoće iz sirovog željeza (C, Si, Mn, P) daje toplotu Okside i S apsorbuje šljaka Kapacitet 400t / 40min. strana 11
12 Electric Arc Furnace rafinacija čelika ruda željeza ubrizgavanje C prirodni gas direktna redukcija kontinualno livenje ugalj recikliran čelik slabovi tanke ploče koksna peć Basic Oxygen Furnace poluge šipke krečnjak Visoka peć livenje sirovog željeza strana 12
13 pločasti materijal ploče cevi Toplo valjani lim Toplo valjani kotur peć za dogrevanje galvanizacija hladno valjani termička obrada premazivanje i finiširanje bešavne cevi poluge i šipke profili valjaonica šipke strana 13
14 Steel Industry Safety in STEEL From Start to Finish 6 44 Continuous casting technology patented Cyberlink technology (HKM) 2 min. VIDEO ONE SUCCESSFUL STORY Hot rolling mills Integral revamp concept 2 min. Integrated Plants for Stainless Steel 2 min. strana 14 Srednja mašinska Srednja škola, mašinska Novi škola, Sad, Srbija Novi Sad, Srbija
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