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OCCASION This Publication Has Been Made Available to the Public on The OCCASION This publication has been made available to the public on the occasion of the 50th anniversary of the United Nations Industrial Development Organisation. DISCLAIMER This document has been produced without formal United Nations editing. The designations employed and the presentation of the material in this document do not imply the expression of any opinion whatsoever on the part of the Secretariat of the United Nations Industrial Development Organization (UNIDO) concerning the legal status of any country, territory, city or area or of its authorities, or concerning the delimitation of its frontiers or boundaries, or its economic system or degree of development. Designations such as “developed”, “industrialized” and “developing” are intended for statistical convenience and do not necessarily express a judgment about the stage reached by a particular country or area in the development process. Mention of firm names or commercial products does not constitute an endorsement by UNIDO. FAIR USE POLICY Any part of this publication may be quoted and referenced for educational and research purposes without additional permission from UNIDO. However, those who make use of quoting and referencing this publication are requested to follow the Fair Use Policy of giving due credit to UNIDO. CONTACT Please contact [email protected] for further information concerning UNIDO publications. For more information about UNIDO, please visit us at www.unido.org UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION Vienna International Centre, P.O. Box 300, 1400 Vienna, Austria Tel: (+43-1) 26026-0 · www.unido.org · [email protected] 0»10 LMTKD NATIONS INDUSTRIAL DKVKIXJPNŒNT ORGANIZATION Development and Transfer of Technology Series No. I I TECHNOLOGICAL PROFILES ON THE IRON AND STEEL INDUSTRY Hggp UNITED NATIONS TECHNOLOGICAL PROFILES ON THE IRON AND STEEL INDUSTRY I L UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION Vienna Development and Traneier of Technology Series No. 11 TECHNOLOGICAL PROFILES ON THE IRON AND STEEL INDUSTRY UNITED NATIONS New York, 1978 The designations employed and the presentation of the material in this publication do not imply the expression of any opinion whatsoever on the part of the Secretariat of the United Nations concerning the legal status of any country, territory, city or area or of its authorities, or concerning the delimitation ot its frontiers or boundaries. References to firm names and commercial products and processes do not imply the endorsement of the United Nations Kdustrial Development Organization (UNIDO), and any failure to mention a particular firm, commercial product or process in connection with the technologies described in this volume is not a sign of disapproval. Material in this publication may be freely quoted or reprinted, but acknowledgement is requested, together with a copy of the publication containing the quotation or reprint. Preface The four technological profiles on the iron and steel industry contained in this publication were prepared for the Industrial and Technological Information Bank (INTIB) of the United Nations Industrial Development Organization (UNIDO), which is a component of the UNIDO programme on the development of technology. INTIB is a pilot operation that began in July 1977 fora period of 18 months. Its work is being concentrated on four industrial sectors: iron and steel. fertilizers, agro-industries, and agricultural machinery and implements. Each of these sectors has priority in other UNIDO endeavours also: sectoral studies, consultations, negotiations and technical assistance projects. The concept of INTIB has its loots in the Lima Declaration and Plan of Action, adopted at the Second General Conference of UNIDO in 1975, and in various United Nations General Assembly resolutions, all envisaging such a service as an essential instrument for the transfer. development and adaptation of appropriate technologies. To increase the share of developing countries in world industrial output from 7 per cent (in 1975) to 25 per cent by 2000, an objective set by the Lima Conference, decision makers must have adequate information on new investments. Those advising the decision makers national industrial information centres. technology development institutes and investment banks also must have this information. The novel character of INTIB, as compared with the services previously rendered by UNIDO, is that it is addressed to the selection of technology before the technology is acquired. INTIB not only draws upon the services available in the Industrial Information Section, where it is housed, but also relies on the expertise of specialists in the Industrial Operations Division of UNIDO and outside experts to process the information obtained from sources within and outside UNIDO relevant to technology selection. As a result of this effort, UNIDO is able to supply information in anticipation of, as well as in response to, demand. An example is the series of technology profiles and monographs being prepared, to which this volume belongs, concerning matters to consider when selecting a technology from a variety of alternatives. The "customers" INTIB is designed to serve include ministries of industry, planning and industrial development institutes, multipurpose technological institutions, and agencies concerned with the transfer of technology. The intention is to serve all those who are responsible for selecting technology, whether in an advisory role or decision-making capacity, in each of the four . lority industrial sectors selected for the pilot phase. Further information about INTIB and its related activities can be had on request by writing to the Chief. Industrial Information Section, UNIDO, P.O. Box 707, A-101 1 Vienna. Austria. These technological profiles were prepared bjfcTp. Mathufy acting as a consultant to UNIDO; the views expressed are those of the consultaiïï~âTWTÎo~not necessarily reflect the views of the secretariat of UNIDO. /|\ EXPLANATORY NOTES References to dollars ($) are to United States dollars. The term "billion" signifies a thousand million. References to "tons" are to metric tons, unless otherwise specified. Parentheses around a figure indicate a minus amount (in tables only). Besides the common abbreviations, symbols and terms, the following have been used in this repor': BF Blast-furnace BOF Basic oxygen furnace DR Direct reduction EF Electric furnace HTGR High-temperature gas-cooled reactor kVA Kilovolt-ampere LD Linz-Donawitz LWS Creusot-Loire and Wendel-Sidelor with Sprunck and Co. MVA Megavolt-ampere Nm3 Normal cubic metres OBM Oxygen Bottom Maxhütte OH Open hearth Q-BOP "Quick, quiet, quality" basic oxygen process SIP Submerged injection process vi j CONTENTS ampler ''"I"' I. WORLD IRON-ORE SURVEY ! Iron-ore deposits ' Africa ' Asia ' Europe ' Latin America Northern America Oceania - Union of Soviet Socialist Republics 2 Production and reserves i Beneficiation 3 Techniques 5 Crushing 5 Grinding 5 Washing 5 Gravity methods 5 Magnetic separation 5 Froth flotation 5 Electrostatic/high-tension separation 5 ¡.ow-temperature magnetizing roasting 5 Dew itering and drying 5 Practice in various countries 6 Canada 6 India 6 Sweden 6 Union of Soviet Socialist Republics 6 United States of America 7 Agglomeration 3 Sintering 9 Pelletizing 9 Cost data 9 Pellet production and heat-hardening " Comparison of sinter and pellets 9 Physical form of iron-ore consumption 10 IRONMAKING 12 Influence of burden constituents 12 Iron ores 12 Iron compounds 12 Silica 12 Alumina 12 Lime 12 Magnesia 12 vii Page Chapter II. IRONMAKING (continued) Manganese oxides '3 Phosphorus '3 Sulphur 13 Titanium 13 Vanadium 13 Zinc 13 Copper 13 Chromium 13 Nickel 13 Arsenic 13 Lead 13 77« 13 Coke \3 Manufacture of metallurgical coke l<* Formed coke Charcoal l5 Fluxes J° Acidfluxes J£ Basic fluxes Alumina Fluorspar Manufacture of pig-iron Blast-furnace operation and technology 1° Raw materials j ' Blast-humidity control J* Oxygen enrichment of blast *° Fuel injection j; High-top-pressure operation 1' Pre-reduced burden 1' Large-capacity blast-furnace 20 Electric ironmaking techniques 24 Open-bath arc furnace 24 Submerged-arc furnaces 24 Pre-reduction of smelting material 25 Economic considerations 25 III. STEELMAKING 27 Processes *' Open hearth 27 Pneumatic processes • Bottom-blown converter 28 Side-blown converter Stora-Kaldo process 28 Rotor process 28 LinzDonawitz (LD)process 28 Bottom-blowing oxygen process 29 Comparison of the OBM and LD processes 29 LWSprocess 30 Q-BOP process 30 SIPprocess 30 Continuous processes viii Chapter Pa*' III. STEELMAKING (continued) Electric processes 32 Resistance method 32 Electric arc method 32 Atomic energy and steelmaking 32 Share of each procesj in steel production 33 Process selection 33 Optimum works scale 33 Cost data 33 ¡V. STEEL CASTING 40 Production of steel castings 40 Annealing 40 Normalizing 40 Ouenching and tempering 40 Flame hardening 40 Ingot casting 40 Bottom-pressure casting 41 Continuous casting 41 Growth pattern of continuous casting 42 Choice of process 42 Cost data 43 Figures I. Typical flow-sheet for a hematite ore from India 7 II. Typical flow-sheet for a magnetite-hematite ^re from India 8 III. Projection of iron-ore consumption by physical form 11 IV. Relation of coke consumption and production to pre-reduced burden 20 Tables 1. World iron-ore production 2 2. World distribution of iron-ore mineral resources 4 3. World pellet production in 1975 10 4. Relation between production of sinter/pellets and pig-iron 10 5. Changing
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