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Iron is one of the most important metals in mechanical engineering, as it is present in sufficient quantities on earth. The extraction of iron can therefore be very economical. However, pure iron is not suitable for use as a construction material. It is much too soft in its pure form and has too little strength to meet most mechanical requirements. For this reason, it is necessary to use alloying additives to give the iron its hardness and strength.
It has been shown that carbon is an excellent alloying element. Within certain limits, carbon has a very high strength and hardness increasing effect and is very cheap compared to other alloying elements. Such a compound of iron and carbon is generally referred to as steel, where the carbon content is less than 2 . The special importance of steel in mechanical engineering is already demonstrated by the daily production of around 4 million tons of steel
Steel is an alloy of iron and carbon, with a maximum carbon content of 2
Iron ore minerals, particularly hematite and goethite, are beneficiated by a combination of size fraction, preconcentration, and flotation in stages Fig. 13.45.Iron ore requires removal of silicate impurities of a finer size by flotation for higher-grade products of 60 Fe. ROM ore at 400600 mm is fed to a primary crusher with product set at 40 mm.
In contrast to the direct reduced iron process, the blast furnace process can be operated on a large scale. The blast furnace process accounts for over 80 of total steel production. Therefore, the blast furnace process will be discussed in more detail in the following.
The flow chart shows the basic steps of how iron ore is used to produce semi-finished products of steel. The individual process steps are explained in more detail in the following articles.
Steel is extracted from iron ores mainly found in sedimentary rocks and is also known as ore smelting. The plants for the production of pig iron or steel are called ironworks.
An ironworks or iron works is an industrial plant for the production of steel from iron ores
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The primary objective of iron making is to release iron from chemical combination with oxygen, and, since the blast furnace is much the most efficient process, it receives the most attention here. Alternative methods known as direct reduction are used in over a score of countries, but less than 5 percent of iron is made this way. A third group of iron-making techniques classed as smelting-reduction is still in its infancy.
Iron processing - Iron processing - Iron making The primary objective of iron making is to release iron from chemical combination with oxygen, and, since the blast furnace is much the most efficient process, it receives the most attention here. Alternative methods known as direct reduction are used in over a score of countries, but less than 5 percent of iron is made this way.
The internal workings of a blast furnace used to be something of a mystery, but iron-making chemistry is now well established. Coke burns in oxygen present in the air blast in a combustion reaction taking place near the bottom of the furnace immediately in front of the tuyeres
The heat generated by the reaction is carried upward by the rising gases and transferred to the descending charge. The CO in the gas then reacts with iron oxide in the stack, producing metallic iron and CO2
Not all the oxygen originally present in the ore is removed like this some remaining oxide reacts directly with carbon at the higher temperatures encountered in the bosh
Softening and melting of the ore takes place here, droplets of metal and slag forming and trickling down through a layer of coke to collect on the hearth.
The conditions that cause the chemical reduction of iron oxides to occur also affect other oxides. All the phosphorus pentoxide P2O5 and some of the silica and manganous oxide MnO are reduced, while phosphorus, silicon, and manganese all dissolve in the hot metal together with some carbon from the coke.
This is any process in which iron is extracted from ore at a temperature below the melting points of the materials involved. Gangue remains in the spongelike product, known as direct-reduced iron, or DRI, and must be removed in a subsequent steelmaking process. Only high-grade ores and pellets made from superconcentrates 66 percent iron are therefore really suitable for DR iron making.
The scarcity of coking coals for blast-furnace use and the high cost of coke ovens are two reasons for the emergence of this other alternative iron-making process. Smelting reduction employs two units in the first, iron ore is heated and reduced by gases exiting from the second unit, which is a smelter-gasifier supplied with coal and oxygen. The partially reduced ore is then smelted in the second unit, and liquid iron is produced. Smelting-reduction technology enables a wide range of coals to be used for iron making.
Oct 01, 2018nbsp018332The goal of the study is to determine the GHG emissions of Chinese iron ore mining. The iron ore production system and the system boundary used are shown in Fig. 1 and include mining, ore processing, and agglomeration stages.. Download Download high-res image 384KB Download Download full-size image Fig. 1.
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