Power Managemanet Steel Industry

Power Management.

In addition to energy management measures such as scrap iron, heated to burn heads 3 heads in a heated tank furnace steel annealing tray taken Tundish the head combustion type exhaust heat from the heated air (Self Recuperative Burner) which practices are still powerful. power management follows.

• Quality control of steel scrap.

Scrap iron affects the power consumption of furnace as scrap steel, if entered into non-metal furnace containing only 1% a result requires more power to fuse 15 kWh / ton steel ingots. And waste electrodes 0.2 kg / ton steel ingots. If 200,000 tons of steel ingots per year savings will be 7-8 million baht per year, so random check separation and mixed scrap metal is important. In addition, if the density of steel scrap entering uncertainties will need to enter more than 2 times per cycle, annealing, while not increasing production. Cause heat loss from the furnace wall opening to enter the scrap steel at 3 and 4 to enter the scrap steel that is 3 times more energy to enter 2 times to 17 kWh / ton if steel 200,000 tons per year to power consumption. from oven uncover 3,400,000 kWh / year, representing more than 8 million baht money per year so it should be compressed to a density appropriate (0.5-0.6 kg/m3).

• The heated scrap steel from the furnace exhaust.

Generally, the heated steel plant scrap steel before entering the hot furnace to be heated is not full. Because of poor quality control, scrap iron. Annealing time to prepare scrap steel inconsistent. Allow time to scrap metal is not warm enough. To avoid such restrictions. The steel scrap can be heated by direct heat to the scrap metal outside the furnace fuel. To heat steel scrap prior to furnace annealing reduces the time 5-10 minutes per round maximum temperature of the heated metal fragments should not be lower than 600 (C to prevent odor and gas. And reduce power by as 30 kWh / ton steel ingots. If you consider fuel required to heat steel scrap equivalent power 10 kWh / ton net result saving 20 kWh / tonne, representing more than 10 million baht income per year.

• Arc furnace using a DC power (DC EAF)

In general, steel annealing furnace will use a Power R.. Using alternating current (AC EAF) because it is easier. Do not have a direct current AC power conversion equipment. But with the advancement of technology. Convert alternating current to cause a large direct current is not a problem using DC EAF makes system stable because of the ripple voltage less. Power AC EAF 3-5% less than using bar electrodes decreased 50% to thoroughly melt steel. Not only just around the electrodes and lower risk.

Energy saving guide for Steel Industrial

Industry about the iron and steel products. Classified as heavy industry. More power. Energy costs account for 20% of production costs. Some of the power of nearly 100 million baht per month or per year more than 1,000 million baht ever. If energy costs only 1% was 10 million baht per year. Power management in the steel industry so interesting.

Energy costs account for approximately 20% of production costs. The other costs include cost of raw materials or scrap steel costs 67% electrodes 8% 2% wage cost insulation oven 3% of power is divided into 60% for electric furnace casting and forming processes. 40% thermal energy from fuel oil, fuel oil and polystyrene Equatorial Hotel. Or natural gas. For steel oven. And head for combustion to heat addition in combustion furnace and heated cylinder heads transfusion and iron foundry Ladle Tundish head burn tray if the machine was divided. R. furnace is a power machine that uses the most energy. Secondary oven is a steel plant in steel tank transfer molding machine and Tundish annealing tray, respectively.

Squandering ways to reduce iron with oxygen directly.

Squandering iron ore by means of oxygen reduction occurs directly before squandering squandering by a blast furnace. Current amount of steel produced by this method squander less than 2 percent of the total volume of squandering the world's steel. Mexico is a country that produced the most. Many plants are plants with capacity of 450 tons of steel per day squandering squandering steel produced by this method is similar to a small grain. When expanded view to see the surrounding porous. Similar hole made in the sponge iron is often called porous (sponge iron) production of perforated metal different from the steel by squandering squandering a blast furnace. Iron ore is ground to provide detailed size 11.5 mm fuel use methane gas, which generally is separated from natural gas. Or carbon monoxide gas. With hydrogen. These gases act as fuel to heat high. And allow oxygen reduction reaction.

Iron ore was ground to flow into the reactor (reactor) from the tower gas heat (heating tower) will flow into the reactors. React with the iron ore is porous iron out. Iron ore to react in the reactor about 10-14 hours long 100 tons of iron ore to steel, perforated steel, perforated 60-65 tons 1 ton require 760-800 cubic meters of methane gas, iron sulfur content is less porous than iron squander that. from squandering a blast furnace. Because sulfur in iron ore were removed by the reaction of oxygen reduction at porous steel will be made to steel.

The perforated steel suitable sources of natural gas. Or carbon monoxide as a volume. Take - Thai municipal project to produce porous iron using natural gas found in the Gulf of Thailand. This project plans to set up factories in the industrial area east coast

Squandering squandering iron with a blast furnace.

From iron ore to steel, we will squander squander squander before using a blast furnace. Which resembles a high chimney. Diameter is 6-12 meters 40-60 meters high and smaller at lower swollen near the base of the furnace directly. To do with external plates. The internal personnel with different fireguard.

By temperature. It's on the kiln car is moving conveyor iron ore and limestone, along with Teanocgk be used to contain fuel stove from above. Beneath a hole blown into the air through the coal to burn. Waste and filth that. Will be a separate channel bottom of the oven. Before Tech took iron melting out. Steel to steel called squandering.

This will also benefit what is not. As vulnerable. Because some substances are called impure substances such as silicon phosphorus sulfur contamination is enormous. And the amount of carbon in iron to squander up to 4 per cent must be made of steel or cast iron. Or other words that speak.

Materials in the production of cast iron or steel, other steel is steel mixed squandering sure enough. Steel production is squandering squandering of a blast furnace is approximately 500-2000 tonnes per day per stove. The average coal consumption of 0.6 tons per 1 ton of steel squander.
Reactions that occur in the kiln. Oxygen reduction reaction is as follows.
Fe2O3 + 3C 2Fe + 3CO.
Fe2O3 + 3CO 2Fe + 3CO2.

Squandering Steel in Thailand.

Steel is a metal key. And use than other metals. Global steel production estimated percentage. 96 average in all of metal each year. The steel industry is. Century Buddhism began around 9, but also obstacles in the production of steel and can not be very time-generation steel (Iron Age) has started seriously in the 20th century, Buddhism is squandering steel from iron ore. The squandering a blast furnace (blast furnace) in the first fuel is wood charcoal. To use coal (coal) currently used Teanocgk (coke) instead of coal, steel production during the 20 century, Buddhism is not good quality steel. Most iron in the form of squandering (pig iron), even a poor quality steel. But the popularity has led to benefits. It features better than other metals. In Buddhist century Sir Henry 23 Best Access Merrill (Sir Henry Bessemer, harbor in 1813 -1893, the British engineers) find a way to squander your steel - better known properties of steel (steel) that. plate hardness can be increased. And other features. Great discoveries of Sir Henry Best Access Merrill makes steel quickly. Time and very low. Considered that the revolutionary steel industry.
There are several types of iron ore. Each has different components. Iron ore is scattered almost throughout the world. But good quality iron ore. Total concentration is high. And a sufficient amount of minerals to produce steel are not many of the players. The following types of iron ore is.
1. Hematite is a mineral right to squander the steel. Of iron ore is in the form of oxides. With chemical formula Fe2O3 that is a red iron ore. Steel has about 70 per cent found in USA - America, Australia, the Soviet Union.
2. Magnetite ore that is suitable to use as squandering iron ore a chemical formula Fe3O4 that is black and steel percentage approximately 72 to 73 found in the United States, Sweden and China.
3. Siderite ore is brown with a low number concentration. And iron in the form of a carbonate chemical formula that is iron FeCO3 approximately 47-49 per cent preferred not to squander it with a minimum amount of iron minerals found in the United States, UK and Germany.
4. Limonite minerals are brown and the iron ore in the form of oxide compounds in a chemical formula that Fe2O3 X (H2O) with iron about 60-65 per cent found in France, the United States.
5. Pyrite in iron ore in the form of supporting a recipe that is light Grand FeS2 is a brown steel approximately 60 percent due to iron in the form of supporting a Grand light. Is not popular to be squandering. Because the sulfur in the ore to make steel, sulfur has been squandering doctor become brittle steel.
In Thailand as the survey. Iron minerals found in many areas, such as iron ore they lean buffalo. Lopburi. Echiyongcan Province, Muang District, all provinces all his nondescript Kanchanaburi him - Steel Nakhon Si Thammarat. Mineral found mostly Hematite minerals and mineral supply some Magnetite enough to unlock the steel industry or squander steel industry has. But the lack of investment. Because the steel industry is squandering the money fund industry.

In the steel industry. Steel production was divided into 2 major methods together is.
1. Squandering iron directly from iron ore. Squandering divided into 2 sub-method approach is squandering squandering steel. The squandering a blast furnace. Steel and squandering squandering way reduce oxygen directly (direct reduction) production by this method after suitable sources of natural gas a lot.
2. The steel used to melt scrap steel in the new electric stove. Steel production by this method does not require iron ore.

Iron and steel production processes.

Production of iron and steel includes the following steps.

1. To get minerals and squandering.

2. Annealing and cooking ingredients.

3. Foundry.

4. The process such as forming iron shots.

Products through Step 4 and then go through a progression that can be. Industry continued. To produce a variety of types of usage such as construction materials, container, tank pressure pipes, automotive parts. Electrical machinery and so on.

In Thailand, iron and steel production will start from the intermediate annealing and casting.

1. To get minerals and squandering.

Author of mineral ore is to be converted into the right size and features to squander such as grinding iron ore to extract the information from the stigma then. May be separated based on different specific gravity (Float) or by magnetic separation (Magnetic separation), the minerals that are too detailed. To bale. (Agglomeration) before entering into oven squander.

Squandering iron ore is converted into steel to increase purity. (% Increase of iron) by removing various contaminants. From iron ore.

2. Annealing and cooking ingredients.

Annealing steel is to heat the steel squandering (Pig iron) or steel, perforated steel scrap to make steel melt temperatures (approximately 1600 ° C).

For steel production. In this annealing process. Will improve the mix of steel by a chemical oxidation as to reduce the amount of carbon and phosphorus. The compounds are added. To reduce the amount of additives and chemicals making steel features desired. . In this process. Contaminants, mainly oxide compounds. Sponsors of the elements that need musical folk drama. To separate the metals from water. We run a separate contaminants that Slag.



3. Foundry.

Cast iron is bringing the steel to melt, then garnish


ingredients in a Hotel for the coagulation of the desired shape.

The cast can be divided into 2 a share.

1. Ingot casting is a casting of water into a steel foundry Tech is not moving (Stationary mold) to cast the ingot (Ingot).

2. Continuous casting (Continuous casting) is the melt water to flow through a steel foundry (Mold) and continued to freeze. "Semi-product success" is Billet, Bloom or Slab, which can be cut and processed through the following processes.

Continuous casting currently popular. Since led to the increase in productivity was (Yield), improve quality, increase productivity and efficiency of investment.

4. The process.

The process is fabricated steel to melt to get the shape and size desired. In addition to improving commercial properties of steel products also. The process includes the processing of hot and cold processing.

For plates over the hot iron can then be used to direct certain. But for some plates will be reduced in size by cold rolled. To get the desired thickness and other reasons as follows.

1. To improve the quality of the skin.

2. To provide desired mechanical properties.

3. To have a thickness less than hot rolled.

4. To control the thickness of the low discrepancy.

Because the iron is hot rolled low over the evening. Therefore, in certain plates are produced from the iron was hot to size up one before. Then cold rolled to make.

Aluminium and steel recycling

Steel and aluminium are common materials in the manufacturing industry. The global steel consumption is around 2 billion metric tons every year and the aluminium consumption is around 30 million tons in 2009. Europe and North American countries are playing a huge role in recycling these aluminium materials.

Aluminum is obtained from bauxite, a clay-like ore that is rich in aluminium compounds. World bauxite resources comprise around 75 billion tones in which the major quantity is present in South America and Africa. More than 3 to 4 kg of bauxite is needed to get one kg of aluminium. By conserving one kg of aluminium you are leaving the earth 4 kg of bauxite ore for your younger generation. Its not just about the resources, even you can save a lot of energy by recycling these precious materials. Results shows aluminium recycling requires only 5% of the energy needed as of the energy required for the primary production of this material. Aluminium cans are the most recycled materials next to steel cans in the world. Around 60 % of the aluminium cans are recycled in US alone by 2009.

The global steel consumption is increasing at a very high rate. Statistics shows an increase of 4% of average steel consumption is recorded in developing countries like China and India. Furthermore analysts predict this consumption rate will be more than 9% by 2012. Approximately around 11 million tons of steel is thrown out as scrap in which more than 60% of the scrap is recycled. Steel recycling is also considered to be an economical recycling process when compared to other precious metals like copper, brass, gold and silver. Reports indicate recycled steel requires only 20% of the energy needed for the primary production of this material from iron ore.

With the statistics reports and other proven results we can come to a conclusion that with this metal recycling the earth's metal resource balance can be sustained only through hard efforts. Though governments are doing their best with new legal laws for recycling it's our responsibility also to save these precious resources for our younger generation. Our responsibility doesn't end with saving these resources but we have to spread the word and encourage others to recycle as much as possible.

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