Pig iron has only limited uses, and most of this iron goes on to a steel mill where it is converted into. Wrought iron is produced by pummeling the pig iron using mechanically driven hammers in a wrought iron works. Originally, the iron was collected in pools called pigs, which is the origin of the name pig iron. The iron ore is first roasted in air to produce ironiii oxide which is mixed with coke and limestone and then further heated to a very high temperature in a blast furnace. The most common ore of iron is called haematite iron iii oxide. The oxygen must be removed from the iron iii oxide in order to leave the iron behind. The haematite reacts with carbon in the cast iron to give pure iron and carbon monoxide gas which escapes. The raw materials used include ore, sinter, coke, lime and various aggregates. Nickel is a strategic element that has many application areas in the industry.
Ironmaking blast furnaces consist of several zones. The most common process is the use of a blast furnace to produce pig iron which is about 9294% iron and 35% carbon with smaller amounts of other elements. This section deals with the types of iron and steel which are produced as a result of the steelmaking process. How a blast furnace works introduction the purpose of a blast furnace is to chemically reduce and physically convert iron oxides into liquid iron called hot metal.
The downward flow of the ore along with the flux in contact with an upflow of. The best known iron ore is called haematite haem means iron, as in haemoglobin it contains iron oxide and many impurities. Aug 24, 2016 the 6minute video explains the mining and processing of iron ore, followed by its conversion to steel. Effective extraction of titanium from rutile by a low. Oct 30, 2012 you always study about science experiments and activities and learn so many new things. With low iron content degree fe extraction of iron from its ore is a long and subdued process, that helps in separating the useful components from the waste materials such as slag. Wrought iron is quite soft and easily worked and has little structural strength.
The purpose of a blast furnace is to reduce the concentrated ore chemically to its liquid metal state. To ensure that the production process maintains a high and stable level of quality, these materials have to be metered precisely and supplied to the blast furnace in batches. Pdf a production of pig iron has been conducted from crushing plant waste. How iron is made material, manufacture, making, history. Blast furnace, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed into the top. Pig iron is a solid form of hot metal, obtained from iron ore or scrap recycling, and it is processed with blast furnace or electric arc furnace. These results indicate clearly that the separation between molten pig iron and reduced ilmenite can be enhanced by hydrogen reduction process, even at lower temperature than that of carbon. In these processes, pig iron is melted and a strong current of air is directed over. This is why the majority of the carbon in the pig iron reacts to form co, and a much smaller fraction or carbon forms co2, and an even smaller fraction of iron oxide feo is formed. Extracting iron from iron ore using a blast furnace. Alloys of irons are used to make cars, nails, bridges etc. The oxidation also raises the temperature of the iron mass and keeps it molten.
Iron ore, as mined, is a combination of iron with oxygen and various other unwanted substances, generally known as gangue. A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals. It is the fourth most common element in the earths crust in its metallic state, iron is rare in the. The refining of iron to make steel is where the carbon content of hot metal is lowered, usually to less than 1 % by an oxidation process in a steelmaking furnace. It is produced by reduction of iron oxides, in the liquid state, in blast furnaces. Iron ore is converted into various types of iron through several processes.
Normal pig iron made in the electric furnace was found to be less suited to the production of openhearth steel than normal blastfurnace pig iron. What is the method of production of pig iron by using a blast. Copper matte is charged into a silica lined converter in extraction of copper. The pig iron can be further refined to produce steel or wrought iron.
Commercial forms of iron there are three major commercial forms of iron. It is a metal that belongs to the first transition series and group 8 of the periodic table. The second process is basic oxygen steel bos process it is the most modern method for manufacturing of steel. Before iron ore can be used in a blast furnace, it must be extracted from the ground and partially refined to.
It constitutes 5 percent by weight of the earths crust, and it is the. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. You might have learnt that metals are extracted from their ores the raw form of metals. Raw materials in blast furnace are iron ore, metallurgical coke and suitable fluxes like dolomite, lime etc. The production of pig iron from crushing plant waste using. Pig iron is an intermediate product of the iron industry, also known as crude iron, which is. Iron fe is a relatively dense metal with a silvery white appearance and distinctive. Aluminium and iron are the most abundant metals in the earths crust. The reduction of contaminants in pig iron that negatively affect material properties, such as sulfur and phosphorus, yields cast iron containing 24% carbon, 16% silicon, and small amounts of manganese.
The extraction of metals and its isolation occurs over a few major steps. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace, using coke as both a fuel and reducing agent. Extraction of iron in a blast furnace reduction haematite o. The process is continuous with raw materials being regularly charged to the top of the furnace and. The 6minute video explains the mining and processing of iron ore, followed by its conversion to steel. With low iron content degree fe process is required for this iron ore waste to be able to use as feed material in smelting process into pig iron. The iron ore is first roasted in air to produce iron iii oxide which is mixed with coke and limestone and then further heated to a very high temperature in a blast furnace. Both these methods reduce the carbon content of the pig iron, which in turn reduces the brittleness property of the metals. If all the carbon is removed from the iron to give high purity iron, it is known as wrought iron.
You always study about science experiments and activities and learn so many new things. This takes place in a blast furnace named after blasts of air 20% oxygen, heated to c, which are blasted into the bottom of the furnace. The bessemer process was the first inexpensive industrial process for the massproduction of steel from molten pig iron prior to the open hearth furnace. Extraction of iron metallurgy blast furnace and reactions. The most common ore of iron is called haematite ironiii oxide.
We are going to discuss in details about the different types of iron in the extraction of the iron part. These materials are loaded into the blast furnace from the top while a blast of hot air is introduced into it from beneath via small pipes known as tuyeres. Pig iron is an intermediate product of the iron industry, also known as crude iron, which is obtained by smelting iron ore in a blast furnace. Environmental problems in mining and transporting the raw materials. The process of preparing pig iron was using hot blast cupola. They are mined and smelted in many countries in both the developed and developing world. Iron fe is a relatively dense metal with a silvery white appearance and distinctive magnetic properties. Since gibbs free energy is always minimized at equilibrium, the reactions and resulting mixtures that require a lower gfe will occur preferentially. Carbothermic reduction of iron ore hametite in blast furnace is a well known process. Iron is extracted from its ore, haematite, by reduction with carbon. The process of the extraction of iron is carried out by the following steps. Processes and procedures in the extraction of iron.
Extraction of iron in a blast furnace iron is also below carbon in the reactivity series, so therefore carbon can be used to reduce it note. Pig iron and refined iron ore pellets briquetted iron can also be used, and. It was found that pig steel produced by the electric shaft furnace was more suitable for steel making in the openhearth than ordinary pig iron, and required less time for complete refining. Nickel pig iron npi production is a new promising process, although it was firstly developed about 50 years ago but it has not been commercially used until some chinese pig iron producers changed their production methods into npi production. The converter is mounted on horizontal pivots around which it can be. A blast furnace for converting iron oxides to iron metal.
The bessemer process involves blowing a strong blast of air through the molten pig iron. The first metallurgical step is to reduce iron ore to metallic iron, a process which is mostly carried out in a blast furnace. Pelletizing a pellet plant contains a series of balling drums where the iron ore concentrate is formed into soft pellets, in much the same manner that one rolls a snowball, to make a pellet about the size of a marble between 14 and 12. Donald wagner suggests that early blast furnace and cast iron production. Cast iron or pig iron it contains 25% carbon along with traces of other impurities like sulphur, phosphorus, manganese etc. Periodically, you let the liquid iron flow out and cool. Apr 05, 2018 metal extraction the occurrence of metals in the earths crust rocks that contain a high enough percentage of a metal to be extracted commercially are known as ores. Then the converter is turned to vertical position for the oxygen to blow, before the lime are added to converter. Iron ores such as haematite contain ironiii oxide, fe 2 o 3.
Haematite is added to the top of the furnace along with coke i. Extracting iron iron and aluminium gcse chemistry single. Pig iron pig iron is an alloy of iron with carbon about 4. Igcse extraction of metals from ores notes igcse and ial. We can melt this again in another furnace a cupola with more coke and limestone and tap it out into a ladle or directly into moulds. In recent years, low grade nickel containing iron nickel pig. Blast furnaces are used to produce pig iron from iron ore for subsequent. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work was conducted in it. But alloys of iron such as steel are highly useful.
It is by mass the most common element on earth, forming much of earths outer and inner core. Blast furnaces produce pig iron from iron ore by the reducing action of carbon supplied as coke at a high temperature in the presence of a fluxing agent such as limestone. Silica in the extraction of copper from copper pyrites ore. The extraction of iron from its ores is quite a technical process. The blast furnace is a huge, steel stack lined with refractory brick, where iron ore, coke and limestone are dumped into the top, and preheated air is blown into the bottom.
Extraction of iron from its ore is the third and the penultimate process in the metallurgy. Table of contentselectric furnace production of pig steelmaking pig iron by electric furnace regulation of carbonpig iron impuritiesloss of iron in the slagadaptability of the process to continuous operationcost of production of pig ironpig iron at the beginning of the use of the electric furnace, for the manufacture of calcium carbide and ferroalloys, experimental work. Extraction of iron from its oxides definition, examples. The links below will take you to information and worksheets, on iron ore and steel. At the same ime, alloying t materials are added to the furnace to achieve the required chemical composition of the final product. Wrought iron is the purest form of iron available commercially available and is prepared from cast iron by heating cast iron in a furnace lined with haematite fe2o3. Processes and procedures in the extraction of iron gulpmatrix. The bessemer process is accomplished in large pearshaped iron vessels called converters which are lined on the inside with silica bricks and can hold upto 50 tons of pig iron at a time. The oxygen must be removed from the ironiii oxide in order to leave the iron behind. The efficiency of the process was further enhanced by the practice of. May 22, 2009 commercial forms of iron there are three major commercial forms of iron. Concentration of ore calcination or roasting of ore reduction of ore. Because of this is can be smelted displaced from iron compounds by heating with carbon coke.
Feb 12, 2018 pig iron is produced in blast furnace by reducing iron ore with carbon monoxide indirect reduction and carbon direct reduction. Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Alloys are nothing but a mixture of different types of metals. Iron compounds are found in rocks we call rocks with high percentages of iron compounds iron ore. The iron, pig iron, collects at the bottom of the blast furnace to be tapped off. Pig iron is not a saleable product, but rather an intermediate step in the production of cast iron and steel. In this metallurgical operation, the ore is concentrated by removing impurities like soil etc.
Most compounds are found as oxides or sulphides, but sulphides are usually converted to oxides. Metal extraction the occurrence of metals in the earths crust. Sep 18, 2019 cast iron has already been mentioned above. The process involves the crushing and washing of ore. Pdf the production of pig iron from crushing plant waste using hot. A mixture of crushed iron ore, coke an almost pure form of carbon and limestone is fed into the top of the blast furnace. In the blast furnace process, the first step on the way towards heavy plate, pig iron is produced from iron ore. Firstly, the carbon in the blast furnace burns with the hot air to form carbon dioxide. The commercial feasibility of the process was established by carrying out smelting trials in. Ld converter is charged with molten pig iron and steel scrap. The sinter process was introduced around 1910 to treat flue dust extracted from. Pig iron blast furnace route international iron metallics association. Iron processing, use of a smelting process to turn the ore into a form from which.
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