Unit 8

UNIT 8
IRON AND STEEL
The first step in the production of steel is to refine the iron ore containing many unwanted impurities, into
cast or pig iron. The refinement of iron ore is usually done in the reducing atmosphere of a blast furnace.
The modern BLAST FURNACE is a huge tubular furnace made of steel and lined with firebrick. Around the
bottom of the furnace are openings (tuvares) through which hot air may be forced. An opening near the top
allows gases to escape. The "charge", consisting of alternate layers of coke and ore into which a "flux",
usually limestone, is mixed, is fed into the furnace, at the top through a bell-shaped opening (hopper)
beginning with a layer of coke .
The coke burns and produces enough heat to melt the iron. The excess carbon from the coke unites with the
iron and lowers its melalting temperature. The melted iron forms at the bottom of the furnace where it is
drawn off when a sufficient quantity has collected. The flux melts and collects the impurities. It floats on top
of the molten iron where it can be drawn off the furnace through an opening higher than the one through
which the iron is taken out. The operation of the furnace is continuous and the right proportions of ore,
limestone, and coke are regularly dumped in at the top of the furnace. Every few hours a batch of blast
furnace iron (pig iron) is drawn off from the bottom of the furnace. The iron coming out of the blast furnace
is called pig Iron because it was formerly cast Into bars called “pigs.” As it contains some impurities and a
relatively large amount of carbon, this pig iron cannot be used directly but requires additional processing
and refining before it becomes cast iron, wrought iron or steel.
CAST IRON is usually made by remelting pig iron and scrap with or without additions of alloying elements
in a cupola or induction furnace, where the pig iron is refined to eliminate some of the excess carbon and
other impurities. Cast irons usually contain 2-4% C. They fall into three main groups: 1. gray cast iron, 2.
malleable iron, and 3. nodular cast Iron.
WROUGHT IRON contains the least amount of carbon of any of the ferrous metals used commercially. It is
manufactured in a puddling furnace. To make wrought iron, pig iron is melted on the hearth of the
reverberatory or puddling furnace which is lined with iron oxide. This process brings about the almost
complete removal of carbon, silicon, and manganese. As the carbon is removed, the fusion temperature of
the iron rises, it becomes pasty and can be rolled up in balls and removed from the furnace. It is then
squeezed through rollers to remove most of the excess slag. The wrought iron Is rolled into muck bars and
finally into commercial forms. Wrought Iron is soft, tough and malleable. It is ideal for ornamental work, as
it is rust resisting, easily shaped, and may be easily welded.
STEEL may be defined as iron combined with 03 to 1.7% of carbon. It is produced by reducing cast iron and
scrap steel in one of several types of furnaces. The furnaces and processes used to produce steel and alloy
steel are discussed in the following unit.
JEDINICA 8
GVOŽĐE I ČELIK
Prvi korak u proizvodnji čelika je rafiniranje željezne rude koja sadrži mnogo neželjenih nečistoća, u liveno
ili sirovo željezo. Rafiniranje željezne rude se obično vrši u redukcijskoj atmosferi visoke peći.
Moderna VISOKA PEĆ je ogromna cevna peć napravljena od čelika i obložena šamotnom opekom. Oko
dna peći nalaze se otvori (tuvare) kroz koje se može potisnuti vrući zrak. Otvor pri vrhu omogućava izlazak
gasova. "Šarža", koja se sastoji od naizmjeničnih slojeva koksa i rude u koje se miješa "topitelj ili obloga",
obično krečnjak, dovodi se u peć, na vrhu kroz otvor u obliku zvona (lijevka) koji počinje slojem koksa. .
Koks gori i proizvodi dovoljno toplote da se željezo otopi. Višak ugljenika iz koksa sjedinjuje se sa željezom
i snižava njegovu temperaturu topljenja. Otopljeno gvožđe se formira na dnu peći odakle se izvlači kada se
prikupi dovoljna količina. Fluks se topi i sakuplja nečistoće. Ona pluta na vrhu rastopljenog gvožđa gde se
može izvući iz peći kroz otvor viši od onog kroz koji se gvožđe izvlači. Rad peći je kontinuiran i prave
proporcije rude, krečnjaka i koksa se redovno ubacuju na vrh peći. Svakih nekoliko sati sa dna peći izvlači
se šarža željeza iz visoke peći (sirovo gvožđe). Gvožđe koje izlazi iz visoke peći naziva se sirovo gvožđe jer
se ranije lijevalo u šipke zvane "svinje". Kako sadrži neke nečistoće i relativno veliku količinu ugljika, ovo
sirovo željezo se ne može direktno koristiti već zahtijeva dodatnu obradu i rafinaciju. prije nego što postane
liveno gvožđe, kovano gvožđe ili čelik.
Liveno željezo se obično proizvodi pretapanjem sirovog željeza i otpada sa ili bez dodataka legirajućih
elemenata u kupoli ili indukcijskoj peći, gdje se sirovo željezo rafinira kako bi se eliminirao dio viška
ugljika i drugih nečistoća. Liveno gvožđe obično sadrži 2-4% C. Spada u tri glavne grupe: 1. sivi liv, 2.
kovno gvožđe i 3. nodularni liv.
KOVANO GVOŽĐE sadrži najmanju količinu ugljika od bilo kojeg od željeznih metala koji se
komercijalno koriste. Proizvodi se u pudling peći. Za izradu kovanog gvožđa, sirovo gvožđe se topi na
ložištu reverberacione ili pudling peći koje je obloženo oksidom gvožđa. Ovaj proces dovodi do skoro
potpunog uklanjanja ugljika, silicija i mangana. Kako se ugljenik uklanja, temperatura fuzije gvožđa raste,
ono postaje pastozno i može se smotati u kuglice i izvaditi iz peći. Zatim se istiskuje kroz valjke kako bi se
uklonila većina viška šljake. Kovano gvožđe se valja u šljake i konačno u komercijalne oblike. Kovano
gvožđe je meko, čvrsto i savitljivo. Idealan je za ukrasne radove, jer je otporan na rđu, lako se oblikuje i lako
se zavariva.
ČELIK se može definirati kao željezo u kombinaciji sa 03 do 1,7 % ugljika. Proizvodi se redukcijom
lijevanog željeza i čeličnog otpada u jednoj od nekoliko vrsta peći. Peći i procesi koji se koriste za
proizvodnju čelika i legiranog čelika razmatraju se u sljedećoj jedinici.

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UNIT 8

IRON AND STEEL

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