Professional Documents
Culture Documents
Rob Boom
Tata Steel Research, Development & Technology, IJmuiden*
Materials innovation institute M2i, Department Materials Science and Engineering
Delft University of Technology, Delft,
The Netherlands
*Until 1 April 2011
Abstract
The role of iron and steel in the metals world is so dominant that
this world is divided into a ferrous and a non-ferrous part, the
latter without a real name. In terms of crude metal production
steel with a peak figure of 1414 million tonnes in 2010 is by far
number one, followed by aluminium with a mere 27 million
tonnes in the same year. Kipling was right in stating that iron is
master of them all. Will his famous statement about East and West
mutatis mutandis also apply to ferrous and non-ferrous metals?
What can the steel industry learn from the non-ferrous industry in
the field of process metallurgy and vice versa?
Examples of synergy between steel and aluminium will be
presented out of the history of former Hoogovens from the
Netherlands with the best of two metals approach and of the early
days of Corus as the future in metals.
In the framework of ULCOS, the European concerted action to
develop a process for ultra-low CO2 steelmaking, an overview
was generated of innovative options for steel production. What
was the interaction with non-ferrous practice in this project phase?
One of the future ways of iron production selected by the ULCOS
team is electrolysis, where the vast experience in primary
aluminium and magnesium production can be of great value.
What to think about the complaint of the blast furnace iron makers
about the decreasing iron content of iron ore if we mirror that to
metal contents in nickel, aluminium and copper ores?
There certainly is a bright future for research institutes covering
both ferrous and non-ferrous process metallurgy and nurturing
mutual interaction between ferrous and non-ferrous as well as
industry and academia, as is proven by the Dutch Materials
innovation institute M2i and McGills Metals Processing Centre
MMPC.
Introduction
The world of metals is divided into two different camps: iron and
steel under the banner of ferrous metals, and all other metals
unified under the banner of non-ferrous. In the Periodic Table 79
of the elements (Figure 1) are metallic in the solid state, and if we
consider the liquid state we can add another two elements, silicon
and germanium, to the family of metals. Another 6 elements
behave metallic in an alloy. It implies that more than 80 metals
are just named after what they are not: ferrous! The explanation of
this curious phenomenon must be found in the strategic
importance of iron and steel for the economy, military power and
security, and infrastructure of nations since the industrial
revolution. It is also clear from the world annular production
figures for the most important construction metals as presented in
Metal
Non-metal
Metallic in alloy
Figure1.MetalsinthePeriodicTable.
Table 1. World production of metals in 2010 in ktonnes/year
Metal
Ironand
steel
Aluminium
Zinc
Lead
Copper
Nickel
Magnesium
Titanium
Production
Datasource
ktonnes/year
1.413.596 WorldSteelAssociation
26.707 InternationalAluminium
Institute
12.860 InternationalLeadandZinc
StudyGroup
9.455 InternationalLeadandZinc
StudyGroup
1.658 InternationalCopperStudy
Group
1.400 InternationalNickelStudy
Group
708 ResearchinChina
100 Rosskil
Metal extraction
Primary metals production through metal extraction from ores is
the only way to produce virgin metals. The starting situation for
iron and steel is different from that for the non-ferrous metals as
the metal content of iron ores is far higher than the metal content
of most non-ferrous metals as indicated in Table 2. Economic
exploitation is directly connected to the metals market price.
Economicallyexploitablecontent
Iron
2570%Fe
Aluminium
5065%Al2O3/2538%Al
Zinc
310%Zn
Lead
112%Pb
Nickel
16%Ni
Copper
0.65%Cu
Iron
For iron this minimum reduction temperature by CO gas is around
700 C, technologically not very problematic. Therefore various
direct reduction processes for iron ore have been developed
making use of carbon or hydrocarbons as reductant, operating at
temperatures slightly above 700 C, and producing iron sponge
(direct reduced iron DRI or hot briquetted iron HBI).
Liquid iron is produced by the blast furnace process that is being
150 C
Aluminium
1100 C
1450 C
2300C
1500 C
Metal refining
The ferrous industry is used to refining the primary iron (hot
metal) from the blast furnace process. Hot metal is almost always
Metal cleanliness
The mechanical properties of a metal are determined by its
composition, structure and texture. For many applications also the
surface properties and the internal cleanliness are important, the
latter determined by the amount and shape of non-metallic
inclusions in the metal.
Steel
For steel metal cleanliness is essential for super deep drawing
applications, for example in automotive external body sheet.
Interstitial free Ti-stabilised ultra-low carbon steel grades,
deoxidised with aluminium, vacuum treated in the steel ladle and
continuously cast with care, are not allowed to have non-metallic
inclusions that show as irregularities in the paint coated car body
outer surface. Non-metallic inclusions in aluminium deoxidised
low carbon steel applied for draw and wall ironing (DWI)
production of cans for carbonated beer and beverage filling, have
to be much smaller in diameter than the ultimate wall thickness
after wall ironing (around 60 m). Otherwise inclusions in the
steel sheet will lead to holes in the can wall that are detected by
the can maker in the production line. Acceptance levels are in the
order of ppms, a few rejected cans with holes per million cans
produced.
The focus in the steel industry on clean steel making is multiple:
minimising formation of non-metallic particles (mainly
oxides) in the melt by sophisticated deoxidation practices,
using oxygen activity measurements, controlled deoxidiser
additions, and effective stirring to achieve equilibrium;
removing non-metallic particles from the melt by stirring and
slag absorption, followed by steel-slag separation;
controlling the shape of aluminium oxides by injection of
calcium metal in order to form liquid calcium aluminates
[9,10,11];
Aluminium
In the case of aluminium production cleanliness of the melt is
achieved by filtering out the non-metallic inclusions that are
immersed in the liquid aluminium. Porous ceramic filters made
out of Al2O3 or ZrO2 are placed in the metal flow prior to entering
the casting mould. Filters are applied with different porosities
expressed in pores per inch (ppi) with excellent results. The
amount and shape of the inclusions in liquid aluminium can be
successfully determined by LiMCA measurements, an innovative
break-through development from Canada [17-18].
the cast could be continued by overflowing the dam and fill the
tundish to the standard 60-70 tonnes steel level. Starting the cast
and priming the filters went well, but the refractory dam broke at
ladle change. No improvement in steel cleanliness between
filtered and unfiltered slab was measured, which suggested that
cracks had formed in the filter dam construction and that the steel
had bypassed the filters. In the next trial the refractory dam was
reinforced by needles in the concrete. Shortly after priming the
lower filters broke and by completion of the sequence also the
upper filters had disappeared completely. Now the dam had
strength, the filters were the weak spots and gave in on the steel
flow pressure and the thermal stresses.
Figure5.Achimneyplacedinatundishtotestprimingof
foamfiltersbyliquidsteel.Thermocouplesandopeningfor
thefoamfilterarevisible[16].
After priming the filter, the steel level outside and inside the
chimney equalised and rose at the same speed. Apparently in this
construction the filter has no significant flow resistance. A trial
with a low dam in the tundish, with two foam filters positioned in
a refractory dam, were successful in aspects of priming. After
casting a sequence of 6 ladles one filter was missing and the other
showed deformation in the flow direction. In this filter deposits of
aluminium oxide were found and no cracks in the filter material
were seen.
A trial with eight filters in a high refractory dam was executed
(Figure 6). The height of the dam corresponded with a level of 55
tonnes of steel in the tundish. In case of full clogging of the filters
Metal casting
After metal extraction, refining and alloying the metal has to be
solidified and shaped by casting. The ferrous and non-ferrous
worlds are quite different in the applied casting techniques. As in
the case of metal refining differences in melting temperature,
metal throughput, and density explain the differences in applied
casting technology. Also differentiating is the reoxidation
sensitivity of iron and the fact that iron oxide does not easily assist
in protecting the melt from atmospheric contamination as does
oxides from e.g. aluminium in casting.
Steel
Continuous casting of liquid steel is the main technology applied
whereby the solidified semi-products have different shapes: slabs,
blooms, billets, rounds, strip, and H- or U-beam blank shapes.
Only for special grades or very thick semi-products ingot casting
is applied. The development for steel strip casting with various
designs (single roll, twin roll, vertical, etc.) has taken a very long
period since the first patent for a twin-roll caster was granted to
Sir Henry Bessemer. Industrial application of strip casting is
restricted to stainless steel by TKS in Germany and carbon steel
grades by Castrip in the USA. The technology is not (yet)
introduced on industrial scale by other companies, and is not
embraced by the steelmakers as should be expected.
Aluminium
The bulk of aluminium is cast by DC ingot casting in shapes of
slabs or tubular semi-products. Continuous casting is applied but
not to the large extent for steel. Hazelett types of casters are
applied for strip casting of aluminium and for casting of other
non-ferrous metals. A promising technology is single belt casting
where liquid metal is fed on top of a moving water-cooled single
metal belt where the metal solidifies starting from the bottom with
a free liquid surface till full solidification is achieved. Belt casting
is operated on industrial scale for non-ferrous metals such as
aluminium, copper and tin. Development for the non-ferrous
metals aluminium and magnesium is ongoing at McGills Metals
Processing Centre in Montreal [26,27,28,29,30,31,32,33,34] with
the ultimate aim to cast steel strip as well. Focus is on
development of an enclosed metal delivery system ensuring isokinetic melt feeding to the strip, and on mathematical modelling
of heat exchange between melt and strip and the critical role of
interfacial thermal resistance between solidified strip and watercooled substrate.
A pilot single belt caster originally from BHP, Australia, is used
for applied research into high speed strip casting of Al, Mg, and
steel sheets. Assemblage, design and improved engineering has
been done in collaboration with the Hazelett Strip Casting
Company.
Discussion
From the examples presented in this paper the picture is
confirmed that the two worlds of ferrous and non-ferrous metals
are clearly separated from each other. It is also demonstrated that
there would be great benefit in learning from each other in terms
of technologies successfully developed in one world to be adapted
in the other world and vice versa. To this end the contacts
between experts and specialists in ferrous and non-ferrous
metallurgy should be enforced. The strong global orientation, the
willingness to collaborate with competitors, the open innovation
attitude combined with the internal focus of the iron and
steelmaking research community, is in itself a strong point for
iron and steel, but makes contact with the non-ferrous colleagues
the more difficult. The balance in terms of tonnage produced and
size of the companies is completely at the ferrous site. The ferrous
community is well organised in terms of institutions such as AIST
(USA), ISIJ (Japan), and VDEh (Germany) supporting their
members in many aspects, organising regular iron and steel
conferences, publicising edited journals, and producing books and
educational material. A few organisations try to incorporate all
metals, such as CIM (Canada), AIM (Italia), IOM3 (UK, also for
glass and polymers) and CSM (China). World wide there are only
a few R&D centres studying all metals, no matter ferrous or nonferrous. CSIRO (Australia), MMPC (Canada) and the Materials
innovation institute M2i (The Netherlands) are examples. National
institutes for metals research such as IMR (Shenyang, China) or
NRIM (Tsukuba, Japan) tend to rather study and develop more
advanced materials by means of world class metals physics than
develop process metallurgical knowledge.
It starts with the change in focus of students education at
universities and graduate schools. Historically first steel as main
direction was replaced by metals, then metallurgy by materials
science, eventually leading to lack of education in process
metallurgy skills. An exception is the reverse specialisation for
graduate education in ferrous technology at GIFT (Pohang,
Korea), stimulated and sponsored by POSCO (Korea).
Some metal manufacturers are active in both ferrous and non-
Conclusions
From the analysis made in this paper the following conclusions
can be formulated:
from the Periodic Table more than 80 metals are named nonferrous, thus after what they are not: ferrous;
iron is by far worlds most important metal produced with an
annual production of about 1.4 billion tonnes in 2010, which
is 53 times more than global aluminium production;
global production data for iron and steel are publically
available, for non-ferrous metals access is restricted;
iron makers can learn a lot from non-ferrous ore
beneficiation experience which will help to explore not
attractive iron ores containing zinc and aluminium;
the ironmaking blast furnace is a well developed
carbothermic redactor of iron oxides;
to reduce emission of carbon dioxide the European steel
industry orchestrated the ULCOS project;
the ULCOS top gas recycled blast furnace will be an
improved low-CO2 carbothermic reductor of iron oxide with
good prospects for carbon capture and storage;
the aluminium industry should combine forces to develop a
carbothermic aluminium oxide reductor making use of
mature ironmaking experience;
the steel industry should learn from the non-ferrous industry
to develop electrolysis of iron oxide through a
hydrometallurgical or pyrometallurgical route;
refining of liquid iron is inevitable to produce steel, and nonferrous metal purification could adopt developed steel
refining practices to a larger extent;
steel scrap is upgraded after recycling whereas non-ferrous
scrap after recycling ends in lower grade products;
cleanliness control of liquid steel demands sophisticated
control and understanding of a chain of processes before start
of casting;
filtering of liquid aluminium to remove non-metallic
particles is highly effective, for high throughput steel casting
filtering does not work;
continuous casting of steel in various forms is state-of-theart, which is not yet the case for non-ferrous metal casting;
strip twin roll and belt casting is state-of-the-art for nonferrous metals and not for steel strip casting;
single belt strip casting with in-line hot rolling is a promising
technology for the production of high alloyed high strength
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