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| MET3034 | Iron and Steel Production | 3+0+0 | ECTS:4 | | Year / Semester | Spring Semester | | Level of Course | First Cycle | | Status | Elective | | Department | DEPARTMENT of METALLURGICAL and MATERIALS ENGINEERING | | Prerequisites and co-requisites | None | | Mode of Delivery | | | Contact Hours | 14 weeks - 3 hours of lectures per week | | Lecturer | Doç. Dr. Fatih ERDEMİR | | Co-Lecturer | Assoc.Prof.Dr. Fatih ERDEMİR | | Language of instruction | Turkish | | Professional practise ( internship ) | None | | | | The aim of the course: | | To provide detailed information about iron-steel production technologies and blast furnace and basic oxygen furnace processes in this context |
| Learning Outcomes | CTPO | TOA | | Upon successful completion of the course, the students will be able to : | | | | LO - 1 : | Explain the enrichment of iron ore. | 1,9,12 | | | LO - 2 : | Learn steel production process. | 1,9,12 | | | LO - 3 : | Learn blast furnace process. | 1,9,12 | | | LO - 4 : | Understand the thermodynamics of steelmaking by the basic oxygen method. | 1,9,12 | | | CTPO : Contribution to programme outcomes, TOA :Type of assessment (1: written exam, 2: Oral exam, 3: Homework assignment, 4: Laboratory exercise/exam, 5: Seminar / presentation, 6: Term paper), LO : Learning Outcome | | |
| Iron ore preparation, enrichment, sintering and pelletizing processes, reduction of iron oxides, hollow and hopper reactions, slag formation, blast furnace operation practices, hot metal operations, other iron production methods. Definition of steel production process, C-O reaction, production of steel, S, P, N, H, DRI (sponge iron) production and use in steel production, alloy steelmaking, deoxidization, secondary metallurgy, continuous casting technology and basic principles |
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| Course Syllabus | | Week | Subject | Related Notes / Files | | Week 1 | Blast furnace (general). Iron ore preparation, crushing-grinding operations. Preprocessing: Sintering and pelletizing | | | Week 2 | Blast furnace: Fe-O phase diagram, Boudouard reaction, reduction of iron oxides; Fixed bed and moving bed. | | | Week 3 |
The effect of solid carbon on the reduction of iron oxides. Thermal reserve zone, chemical reserve zone. Reduction of iron oxides by direct reduction and indirect reduction. Effect of reduction of gangue components and additives | | | Week 4 | Empty and hopper reactions. Slag formation on blast furnace. Metal-slag reactions. The concept of slag and slag basics. Si and Mn slag-metal distribution ratios. | | | Week 5 | High-temperature carbon and sulfur. Desulfurization process in hot metal. Rogue elements in the blast furnace | | | Week 6 |
Blast furnace operating practices: Pressure reduction, pumping operations, hot air characteristics: Hot air temperature, oxygen enrichment, hot air moisture content, auxiliary fuel injection, high furnace peak pressure. | | | Week 7 |
Other iron production methods | | | Week 8 |
Midterm | | | Week 9 |
Introduction to steel production. Steel production furnaces. Basic oxygen furnace. The thermodynamics and mechanism of the C-O reaction. Oxidation of Si, Mn and P in BOF. Oxygen potential in steel production. Oxidizing slag, reducing slag. | | | Week 10 | Oxidation of other elements. Alloy steel construction. High chrome steel construction. Stainless steel production; VOD-AOD processes. | | | Week 11 | Oxygen depletion. Thermodynamics and kinetics of oxygenation. Oxygen removal with Mn, Si, Mn-Si, Al and Al-Ca (O) | | | Week 12 |
Hydrogen, nitrogen and sulfur in steel production | | | Week 13 |
DRI (sponge iron) production and use in steel production. | | | Week 14 | Continuous casting technology and principles. | | | Week 15 |
General overhaul | | | Week 16 |
Final exam | | | |
| Method of Assessment | | Type of assessment | Week No | Date | Duration (hours) | Weight (%) | | Mid-term exam | 8 | 07/05/2021 | 1 | 50 | | End-of-term exam | 16 | 28/06/2021 | 1 | 50 | | |
| Student Work Load and its Distribution | | Type of work | Duration (hours pw) | No of weeks / Number of activity | Hours in total per term | | Yüz yüze eğitim | 3 | 14 | 42 | | Sınıf dışı çalışma | 2 | 14 | 28 | | Arasınav için hazırlık | 8 | 1 | 8 | | Arasınav | 1 | 1 | 1 | | Dönem sonu sınavı için hazırlık | 12 | 1 | 12 | | Dönem sonu sınavı | 1 | 1 | 1 | | Total work load | | | 92 |
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