The film was shot as a film course "Technology of Metals" for students of vocational schools. The film shows open-hearth steel production, the structure of open-hearth furnaces and the technology of the process.
Open-hearth shop with furnaces with a capacity of 400 tons.
Division of furnaces by the type of fuel used in them.
Cartoon explaining the design of a gas open-hearth furnace.
Loading the furnace with batch.
Boiling metal.
Continuation of the cartoon explaining the design of a gas open-hearth furnace.
Cartoon explaining the design of a fuel oil open-hearth furnace.
Given the long-term operation of the furnace, high melting temperatures and the nature of the physical and technical processes, various refractory materials are used for laying the elements of the open-hearth furnace.
For example, dinas, magnesite, chrome-magnesite and magnesite-chrome brick.
Division of furnaces into acid and basic.
Definition of an acid open-hearth furnace.
Definition of a basic open-hearth furnace.
Mixer department.
It is usually located next to the open-hearth shop.
The mixer is used to create a reserve of liquid pig iron.
In addition, the chemical composition and temperature of the pig iron are equalized in it, and sulfur is partially removed.
At secondary ferrous metal plants and in scrap cutting shops, scrap metal is prepared for remelting.
Sheet trimmings and other lightweight scrap metal are bundled.
Oversized scrap metal is cut by flame cutting or shears.
Large pieces of metal are broken up in a pile driver.
A batch yard, which is used to store batch and filling materials and to prepare trains with batch.
The batch yard consists of a section for storing bulk materials and scrap metal.
Inside the batch yard, there are two through railway tracks.
Unloading for wagons and loading for trains of trough bogies.
Unloading scrap from wagons.
Unloading bulk materials.
Open-hearth furnace, Scrap metal, The mixture
Iron ore is used in open-hearth production as an oxidizer.
Sometimes, sinter or scale is used instead of iron ore.
Limestone, freshly burned lime, bauxite and other fluxes are used to form slag in the main open-hearth furnace.
When collecting the charge, the scrub and bulk materials are loaded into molds.
The loaded molds are sent to the open-hearth furnaces.
Depending on the composition of the charge, there are three main types of the open-hearth process.
Scrap process, in which the main part of the charge is scrap.
Scrap-ore process, when the basis of the charge is liquid iron.
Ore process, in which the charge consists only of liquid iron.
A furnace with a scrap-ore process is demonstrated.
Furnace filling.
Worn sections of the furnace are repaired using a filling machine.
After filling, the charge is loaded layer by layer.
First, a portion of the iron ore is loaded.
Then, after the ore has been heated, all the limestone and the rest of the iron ore are loaded.
After the bulk materials have been heated, the scrap is loaded.
During the scrap heating, the thresholds of the charging windows are sprinkled with dolomite.
After the solid charge has been heated well, chutes for pouring liquid cast iron are installed.
The cast iron is poured. 15-20 minutes after all the charge materials have completely melted, the slag is drained.
To control the chemical composition of the metal, a sample is taken and sent to the laboratory.
After the steel has been brought to the required chemical composition and the desired temperature, the steel is tapped from the furnace.
Before tapping the melt, the steel tapping hole is cut.
The plug of refractory clay and magnesite powder that fills the hole are removed.
The sintered crust in the neck of the hole is burned with oxygen.
The steel is poured into the pouring ladles through a special chute.
The melting process is completed.
After the melt is tapped, the bottom is thoroughly inspected, then drying of the steel tap hole is started by throwing a couple of shovels of magnesite powder into it.
After mixing with the slag and metal remaining in the hole, the magnesite powder is removed.
On the furnace side, the steel tap hole is covered with a layer of magnesite powder.
Then, on the trough side, using rammers, the hole is filled with wet magnesite powder.
At the outlet, it is plugged with a refractory clay plug.
A cartoon explaining the processes that occur in an open-hearth furnace during melting.
Chemical formulas of the process.
Removal of primary slag.
The final stage of melting is the preliminary deoxidation of steel in the furnace and the final deoxidation in the ladle.
The addition of deoxidizers stops the burnout of carbon and provides the specified chemical composition of the steel.
Substances used as deoxidizers.
Chemical formulas of the process.
Special elements are introduced into the composition when obtaining alloy steels.
List of elements and their characteristics.
Martin process, Deoxidation of steel, Alloying of steel
After adding deoxidizers and alloying additives, the steel is fed to the casting unit.
Steel is poured from the top.
The steel goes directly from the ladle into the mold.
A cartoon explaining this method of metal pouring.
A cartoon explaining siphon pouring.
A cartoon explaining continuous steel pouring.
In the cutting zone, the ingots are cut into measured blanks, which are transported to the warehouse or fed hot to the rolling mill.
A cartoon explaining vacuum processing of steel.
A cartoon explaining the process of metal crystallization when pouring it into molds.
Open-hearth furnace.
Alternating frames of the open-hearth smelting process.
A cartoon explaining the use of oxygen during smelting.
An experimental two-bath open-hearth furnace.
A cartoon explaining the operation of such a furnace.
Thermal control devices.
Panorama of the open-hearth shop.
Open-hearth furnaces, Steel spill, Crystallization of metal