Chapter 3 - Iron and Steel Production

Mechanical Engineering Department
JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION

Types of Iron Ore 1
Characteristics of Iron Ore 2
Iron Production Process 3
Steel Production Process 4
Iron is an element in the periodic table that
has the symbol Fe and atomic number 26
metallic iron is produced from iron ore and
rare elements found in free
Iron is the main and most abundant metal
use
physical properties can be modified
price is cheap and easily available
most of the steel used was not in a pure
rocks that contain minerals of iron and other
elements
composed of elements or compounds such
as oxides, sulfides, sulfur, silicon, etc.
have different color
is the main ingredient in the production of
pig iron
It was not in its pure form
have 40% - 65% iron content
is the highest of all iron ore is found
black to reddish brown
has 72.4% iron content
available in the form of land or a brick
have magnetic properties
blackish color
iron content of 50% and 50% sulfur
color is golden
found in crystal form
containing iron sebayak 20% - 55% and a
water content of 40%
yellow color is brown, but when the water is
removed it will change the color of
haematite ore
have 25% - 30% iron content
color reddish or blackish
obtained in the form of bricks
iron content of less than 30% and is
otherwise carbon and phosphorus content
Color gray ore
has a sulfur content of 50%
golden
obtained in the form of bricks

with 50% silicon content
can be divided into several types, namely
kamosite, stillprunit, gururite and
minnesotite
iron content of 30%
yellowish brown
can be classified according to the type of
`gauge 'which existed as to whether` gauge
that is rich in silica-rich or calcium oxide
(CaO)
1. grade
- Contains as much iron oxide
2. density
- Not too heavy or too fragile.
3. genuineness
- Have the lowest content of foreign material may
4. uniformity
- Have a uniform composition of the group to
another group
Step 1 :
Concentration

Step 2 :
Calcination

Step 3 :
Smelting

The ore is crushed in
crushers and is
broken to small
pieces. It is
concentrated with
gravity separation
process in which it is
washed with water to
remove clay, sand,
etc.

The ore is then
heated in absence of
air (calcined). This
results in
decomposition of
carbonates into
oxides and then
ferrous oxide is
converted into Ferric
Oxide.
The concentrated ore
is mixed with
calculated quantity of
coke, limestone and
the mixture is put in
the Blast Furnace
from top.

3 2 2
2 3
CO Fe 2 O FeO 4
CO FeO FeCO

Blast furnace consists of a vertical steel shell ~100 ft
high & ~ 21 ft dia and lined with refractory material.
It has a charging arrangement (Bell & Cone) at the top.
Raw material is charged by a skip car through this
charging mechanism into the blast furnace.
It has a means of running off Pig iron & Slag at the
bottom.
Air is blown in near the bottom of the furnace. This
forced draught increases the speed of combustion &
maintains the necessary high temperature.
Cooling water is circulated around the Bosh area in
order to protect the furnace from high temp.

raw material brought to the top of the
furnace by car penangkut
it is inserted into the furnace through the
distributor moves and through the use of a
bell
This bell function for controlling the gas load
loss
continuous hot air sprayed through a number
of openings called `TUYER '
boiler used to heat the air up to 1100 C.
air cooled and hot gas flow repeated in the
opposite direction through the boiler
to supply continuous hot spray, each boiler
furnaces have some work on a rotational
basis
iron is removed from the furnace every 2
hours
molten iron and prop separately removed
through a hole in the bottom of filter
Iron ore + coke + limestone + air

iron + slag + gas

carbon in coke combustion with oxygen in
the air spray
reduction of iron oxide to
flush `gauge iron ore and ash with limestone.
capital and operating costs are high
regulation of iron composition is
relatively weak
small furnace that uses coke is not
efficient
To produce one ton of pig iron, we need raw
materials as follows:
2 tone iron ore+ 1 tone coke+ 1/2 tone limestone

1 tone iron

* Raw materials must be added all at once
used for smelting iron ore to make pig iron.
pig iron containing 93% pure iron, 3% - 5%
carbon, silica, sulfur, phosphorus and
manganese.
main ingredients for cast iron, wrought iron
and steel.
props used for road and building blocks.
In the beginning, it is IRON ...
Then, it became IRON Chartered ...
... finally, STEEL
is a very valuable metal
most types of metal and widely used
produced through the oxidation process that
reduces the amount of carbon, silicon,
manganese, and sulfur forforus in a mixture of
molten pig iron and steel scrap
1. In the field of construction and
building bridges .....
2. In the automotive sector ....

3. For daily use:
cans, pots, containers, etc.
it uses pure oxygen
can move horizontally and vertically
while leaning state, furnace filled with molten iron
and scrap iron 30%
during the vertical, boost oxygen with high-speed
fluid is directed kepermukaan content
Oxygen is cooled with water
Some carbon is converted into gaseous oxides
An old result when the oxide reacts with limestone
furnace is tilted to the horizontal position to produce
mild steel melting
furnace reversed to remove the prop
able to produce high quality steel quickly of 80
tonnes per hour
have a high capacity and easy to operate
low oxygen consumption rate
appropriate to increase the grade of steel
using the supplied natural oxygen jet
produce 120 tons of steel in the first 4 hours.
has a curve shape as a convex cylinder
made of steel and coated with heat-resistant brick
The cap can be removed and there is a three-way, or
opening where carbon electrodes can be moved freely
use coolant through channels outside the furnace
copper
1. charging
charge materials containing steel scrap, pig
iron, iron oxide and lime added to the furnace
electric current is passed to the carbon
electrodes for electric arc supply
2. smelting
electric arc with high heat will melt the charge
material oxygenated
silicon, and phosphorus mangganes start oxidized
and mixed with lime to form the basic prop
no metal is lost as carbon electrodes burn
3. isolation
phosphorus transfer depends on the basic prop in
calcium oxide
lime, iron oxide flourospar and mixed to form a
fulcrum that react with impurities
composed of steel required to developFeS + CaO +
C CaS + Fe + CO

4. closure
Oxidized steel using aluminum, Ferro-Silicon or
Ferro-Mangganes
To take steel, prop knitted or poured from the
surface first and then removed or drained through
the hole / channel exit by tilting furnace
sulfur transfer or change is appropriate.
combustion can be controlled and managed
effectively.
no oxidizing gas to produce high quality steel.
temperature can be precisely controlled.
addition of alloy elements can be made correctly.
furnaces are free from dirt and smoke.
1. Briefly explain THREE (3) types of iron ore on the
surface of the earth.
2. Mention THREE (3) types of furnaces to produce the
production.
i. Iron.
ii. Steel.
3. What is the charge material is included in the
following furnaces:
i. Bagas furnace.
ii. Electric arc furnace.


Chapter 3 - Iron and Steel Production

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Mechanical Engineering Department

JF302 MATERIAL TECHNOLOGY 1 CHAPTER 3 : IRON AND STEEL PRODUCTION

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