Film course on the topic of the basics of metallurgical production. The film examines the types of furnaces for steel smelting, the technology of steel production in each case considered.
Open-hearth shop.
Open-hearth furnace.
Electric furnace.
Tapping steel into molds.
Cartoon explaining the design of an open-hearth furnace.
Cartoon explaining the design of the open-hearth furnace working space.
Charging windows for loading remelted materials.
Steel tapping hole.
Cartoon explaining the design of open-hearth furnace heads.
Types of heads.
Cartoon explaining the fuel supply to the working space.
Cartoon explaining the methods for achieving the temperature required to carry out the open-hearth process.
Cartoon explaining the role of diverter valves in the process of removing combustion products.
The technological process begins with the operation of filling the sections of the furnace working space destroyed during the previous melt with magnesite powder.
Magnesite powder is applied to the damaged lining using a filling machine.
The required amount of charge materials is loaded into the furnace.
Steel scrap.
Limestone.
Bauxite.
Iron ore.
Pellets.
View of the charging windows.
Types of open-hearth process.
Scrap-ore process.
In this process, the solid charge contains 60-65% of liquid iron.
Pouring liquid iron into the furnace.
Before this, false thresholds are made in the charging windows, which hold the melt during melting.
During melting, scrap dissolves in the high-carbon cast iron melt.
A cartoon explaining the formation of slag during steel melting.
After the charge has completely melted, the finishing period begins.
Finishing includes two stages. 1 - ore boiling. 2 - pure non-ore boiling.
During ore boiling, iron ore and slag-forming materials are added to the bath.
A cartoon explaining the effect of additives on the smelting process.
By the end of finishing, pure boiling occurs.
Its task is to bring the metal composition to a specified carbon content and heat it to a temperature of 1600-1620 degrees, ensuring normal pouring of steel.
A cartoon showing the measurement of temperature in the furnace.
Taking a sample to control the chemical composition of metal and slag.
Sending the analysis to the express laboratory by pneumatic mail.
Laboratory.
Carrying out an express analysis, which allows for timely monitoring and adjustment of the composition of the smelted metal.
Upon reaching the specified carbon content in the melt and reaching a temperature of 1600 degrees, preliminary deoxidation begins.
For this, ferromanganese and ferrosilicon are added to the furnace.
A cartoon explaining the deoxidation processes.
In the production of alloy steels, alloying elements are introduced into the metal during finishing and at the end of the melt.
The steelmaker cuts the steel tap hole and the steel enters the ladle through the chute.
For the final deoxidation of steel, the most complete purification from oxygen, silicon and aluminum are used, which are added to the metal during tapping.
A cartoon explaining the method of intensifying open-hearth smelting.
New two-bath open-hearth units.
A cartoon explaining the operation of such units.
The main advantage of the open-hearth method is the ability to process relatively cheap metal charge - scrap.
Footage from the open-hearth furnace shop.
Open-hearth furnace, Steel, The mixture, Slag, Magnesite, Lining, Cast iron, Additives, Deoxidation, Alloying of steel
Oxygen converter.
Cartoon explaining the converter design.
Rotation mechanism used to tilt the converter toward the pouring or loading bays.
The operator controls the loading of scrap into the converter.
Pre-weighed pig iron is poured.
Dosed bulk materials are automatically fed at the signal from the control panel.
Cartoon explaining the oxygen supply and the reactions that occur in the converter when it is supplied.
Purging the converter with oxygen.
Purging is carried out from 12 to 28 minutes.
At the end of the purge, the temperature is measured and a metal sample is taken.
Having brought the steel to a specified composition and temperature, it is released into the ladle through the steel tap hole.
Deoxidation of oxygen-converter steel is carried out in the ladle during tapping.
The steelmaker introduces alloying elements in the form of solid ferroalloys.
They can be introduced both in liquid form and in the form of exothermic mixtures.
The slag is drained into the slag pan.
The CB at the plant.
One of the advantages of converter production is automation of control and monitoring of the melting process.
Electric arc furnace.
Since in electric arc furnaces heating of metal to high temperatures can be carried out in non-oxidizing conditions, high-quality steels are smelted in them.
Alternating frames showing products in which such steels are used.
Cartoon explaining the structure and operation of a three-phase electric arc furnace.
Mechanism for lifting and turning the roof with electrodes.
Before loading, remove the remains of metal and slag.
Refueling is carried out with magnesite powder using a refueling machine.
Loading of the charge from above with a basket with an opening bottom.
Cartoon explaining the loading of the furnace.
Lowering the roof and turning on the current.
Electric arcs are excited.
Under the influence of the high temperature of the arcs, the charge under the electrodes melts.
Cartoon explaining this process.
The automatic regulator maintains a constant arc length.
The steelmaker supplies oxygen to the furnace.
Electricity meter.
The use of oxygen shortens the melting period and reduces energy consumption.
After the charge has completely melted, the oxidation period of the melting begins.
Its task is deep dephosphorization, heating of metal, induction of active lime-iron slags and boiling of the bath.
During the entire oxidation period, ore and lime are repeatedly introduced into the bath.
This forms an active liquid-mobile slag, which absorbs the phosphorus of the metal.
During this period, a lot of slag is pumped out of the furnace.
Cartoon explaining the removal of hydrogen and nitrogen from molten metal.
Slag pumping.
Checking the carbon content in the bath.
Metal deoxidation.
Sulfur removal.
Cartoon explaining the process of electromagnetic stirring.
Deoxidation is carried out by sedimentary or diffusion method.
In the sedimentary method, deoxidizers are introduced into the bath.
In the diffusion method, lime, fluorspar, fireclay scrap are loaded into the furnace and refining slag is introduced.
In this case, metal deoxidation is achieved due to the transition of ferrous oxide dissolved in steel into slag.
Loading nickel.
The order of introduction of alloying additives depends on the affinity of alloying elements to oxygen.
During melting and before tapping, the temperature is measured, metal samples are taken to control the composition of the steel.
The smelted metal is tapped into a ladle.
During tapping, alloying with titanium and final deoxidation with aluminum are carried out.
Various furnaces for smelting steel.
Converter, Scrap, Cast iron, Steel, Slag, Electric arc furnace, The mixture, Electromagnetic mixing, Deoxidation, Alloying additives