End Sem Question Paper

End semester Exam – April 2022
MT 315 – Alternative Routes in Iron and Steel Making

Department of Metallurgical Engineering
Indian Institute of Technology – Banaras Hindu University
Please submit the answer sheets by MS teams. The deadline to return the answer sheets is by
8:00 AM on 28/04/2022. Late submissions will not be evaluated.
Some of the questions require the usage of your roll numbers. If the answers turn out to be
absurd (unrealistic) values, it is fine. The idea is to use your own numbers and solve the
problem.
Total Marks: 35
Answer the following questions.
1. Determine the ratio of diffusivity of C in gamma iron at 500K and 1200K
respectively, given that Do of carbon in steel is 1.5 x 10-5 m2/s. Activation energy of
diffusion is equal to last two digits of your roll number. If your roll number is
19145048, take the activation energy as 48 kJ/mol. Assume Arrhenius type
dependence for diffusion with temperature and solve the problem. (3 Marks)
2. Consider a spherical haemetite ore particle. After a certain amount of reduction in one
of the DRI making processes, the particle now contains some Fe2O3, Fe3O4, FeO and
Fe in varying amounts. You can assume that the phases are distributed in a kind of
concentric fashion. Describe how one can characterize the particle to evaluate the
fraction of each of the phases, porosity present in the particle. (4 Marks)
3. Sponge iron can react with oxygen and moisture in ambient atmosphere. The reaction
is as follows: Fe + H2O + (1/2) O2 = Fe(OH)2 , ΔHf = -x kJ/mol at 25°C and 1 atm. x
is equal to the last two digits of your roll number. If your roll number is 19145048,
take the enthalpy of formation as -48 kJ/mol. What is the amount of heat produced for
1 kg of sponge iron? (2 Marks)
4. Assume that you have access only to steel scrap material and you want to produce
steel of various grades. Do you think it is possible to produce all kinds of steel? Give
reason(s) for your answer. (3 Marks)
5. Describe HYBRIT process of DRI making. Give its salient features. (3 Marks)
6. What is the difference between the gravimetric density and theoretical density in
sintered iron ore pellets? [Write only bulleted points to convey the difference. Excess
information will lead to penalty and the question will be marked zero without
evaluation] [3 Marks]
7. Calculate the theoretical density of directly reduced iron at room temperature (23 oC).
Atomic radius of Fe is 0.126 nm. Atomic weight of iron is 55.84 g/mol. Is it possible
to achieve the theoretical density in practice for directly reduced iron? In which case
you are supposed to reach closer to the theoretical density: i) Directly reduced iron ii)
Iron made in blast furnace and then cast. Justify your answer. Your justification in the
above two cases should not exceed 25 words. In case it exceeds, the answer will not be
evaluated. [3 Marks]
8. Iron ore fines are being sintered in a plant, which produces DRI. The sintered pellets
are cylindrical in shape with ‘R’ as its radius and ‘H’ as its height. Would you like the
pellet to be porous in order to maximize the productivity? Justify your answer in not
more than 20 words. In case of a porous sintered pellet, it is observed that cuboidal
shape pores only form in the pellet and they coalesce along their body diagonal. In such
a situation would you want the pores to be percolatively connected? Justify your answer
in not more than 20 words. Develop a model in 2D and then extend it to 3D to show as
to how the size of the cuboidal pores and its volume fraction should be regulated to
maximize productivity. Clearly state the assumptions in your model. Should two
models in two different answer scripts match, both of them would be subjected to a
grand viva spanning over all the subjects taught so far and the final grade would depend
only on the grand viva. [5 Marks]
9. In a DRI process Fe2O3 is being reduced to Fe3O4 by the reaction

3Fe2O3 + CO = 2Fe3O4 + CO2
The Gibbs Free Energy for the reaction is ‘G’ and the Helmholtz Free Energy for the
reaction is ‘A’ at the temperature ‘T’. As it is a DRI process, Fe3O4 is growing over
Fe2O3. In such a situation develop model that would help you to estimate the interfacial
strain that would be generated between the reactant and the reduced. Justify your steps
in less than 20 words each. Atomic radius of Fe and oxygen are 0.126 nm and 0.073
nm. Assume that atomic radius changes by 10% of its previous value for change of its
each oxidation state.
Hint: Fe2O3 is hexagonal with 2/3 octahedral void filled and Fe3O4 is cubic with ½
octahedral void filled and 1/8 tetrahedral void filled.
Caution: In case two models match in approach, both the proposers would be subjected
to a grand viva in order to decide their fate!!! [5 Marks]
10. In how many ways smelting reduction process can be classified? What are the
advantages of fluidized bed reduction? What are the recommended steps that should be
followed in order to make the smelting reduction process economical. What do you
understand by raceway in a fluidized bed and what is its hysteresis? [4 Marks]

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End semester Exam – April 2022

MT 315 – Alternative Routes in Iron and Steel Making

9. In a DRI process Fe2O3 is being reduced to Fe3O4 by the reaction

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