Extraction of Iron

Iron is about 21 % of total metal of earth’s crust and 6.2 % of total elements.
It belongs to transition group of the periodic table. Its electronic
configuration is 2,8,8,6,2. Some important ores of Iron are listed below:-
i). Hematite Fe2O3
ii). Magnetite Fe3O4
iii). Limonite Fe2O3.H2O
iv). Siderite FeCO3

Hematite:-
Hematite, mineral and the most abundant ore of iron, composed of ferric
oxide, Fe2O3. It is widely distributed over the world, occurring in rocks of all
ages. In the United States hematite makes up about 50 percent of all the iron
ore mined. The chief iron-ore districts in the U.S., and probably the most
important hematite regions in the world, are located along the shores of Lake
Superior in Michigan, Wisconsin, and Minnesota. Extensive deposits are
also found in the Appalachian region extending from New York to Alabama,
with particularly noteworthy deposits in eastern Tennessee and northern
Alabama. Hematite occurs in rhombohedral crystals, called specular iron in
massive formations, and in earthy forms, called red ocher. The crystals are
translucent, range in color from dark gray to black, and have a brilliant
metallic luster; the earthy varieties are lusterless and red.

Main steps involved in extraction of iron from its ore hematite are given
below:-
1.) Concentration of ore:- First of all ore is crushed into minute
particles and the crushed ore is concentrated by gravity separation
method.
2.) Calcination:- Concentrated ore is calcinated in furnace. During
calcinations moisture is removed. Impurities like Sulphur changes
into Sulphur dioxide and Arsenic into arsenic oxide, Phosphorus to
Phosphorus oxide all escape out in the form of gases. Due to presence
of some ferrous carbonate iron changes into iron oxide.
3.) Smelting:- Iron oxide is reduced with carbon. Process of smelting is
done in a furnace. Calcinated iron is added in blast furnace along with
coke. Coke serves as fuel as well as reducing agent. Lime is also
added in furnace which serves as flux. The following reactions takes
place in the furnace:-
a). At the base of the furnace:- Coke reacts with oxygen to produce
Carbon dioxide which moves up and lot of heat is produced.
C+O2 CO2
 As the Carbon dioxide moves upward it is brought in contact with
coke and get converted into Carbon monoxide.
CO2+ C 2CO
At this zone temperature is 1475-1575 K.

b). In the middle of the furnace:-Here temperature is about 1075 to 1275

K. In this region calcium carbonate decomposes to produce calcium
oxide and carbon dioxide. Calcium oxide so produced combines with
silica to form slag.
CaCO3 CaO+CO2
CaO+SiO2 CaSiO3
Calcium Silicate (slag)
c). At the top of the furnace:- In the top of furnace the Iron oxide react
with carbon monoxide to give liquid iron which moves towards the
bottom of the furnace and settled there. This iron is called cast iron.
Fe2O3+3CO Fe+CO2
PROJECT SUBMITTED BY:--
GOVT. GIRLS SEC. SCHOOL
URMAR TANDA(HOSHIARPUR)
SUBJECT OF THE PROJECT:--
EXTRACTION OF IRON ORE