14/7/2014

Diploma in Mechanical Engineering (Material)

JF 302 MATERIAL TECHNOLOGY 1

www.pis.edu.my

CLO 1 : Explain various types of materials used in

manufacturing industry.

Week 4

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Iron production

Understand the iron production

Understand steel production

steel production

carbon steel

alloy steel

cast iron

Ferrous metals are iron based metals which include all varieties of irons and
steels. Non ferrous metals are not iron based metals.

Describe the plain carbon steel

Describe the alloy steel

Metals

Describe the cast iron

Ferrous

Iron

Non-ferrous

(Chapter 5)

Steel

Fig 2.0 Classification of ferrous materials

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Iron production

steel production

carbon steel

alloy steel

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cast iron

Iron production

steel production

carbon steel

alloy steel

cast iron

Fig 2.1 Types of iron ores

Iron are divided into wrought iron and cast iron.

Wrought iron is a metal contains high purity iron and iron silicate. It is very
low in carbon and the iron silicate or slag is distributed throughout the base
metal in fibres which gives it a woody or fibrous appearance when fractured.
Cast iron is fundamentally an alloy which major elements are iron, silicon and
carbon.
The principal methods of manufacturing of iron is:
a. Blast furnace

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Types
1. Magnetite Irons

containing 72.4% irons, has magnetic properties and black in colours.

Characteristic

2. Carbonate Irons

containing less than 30% irons, others are carbon and phosphorus.

3. Hematite Irons

containing 40% - 65% irons and dark brown reddish in colours and sometimes
added with magnetite sulphate.

4. Limonite Irons

containing 20% - 55% irons and 40% water, yellow brownish in colours.

5. Pyrite Irons

containing 50% irons and 50% sulphur, gold in colours and found in crystalline
structure.

6. Taconite Irons

containing only 25% to 30% irons, reddish or blackish in colours.

7. Sulphate Irons

containing 50% sulphur, gold in colours and has few types such as Phyrito Pyrite,
Marcasite and Phynorite

8. Silicate Irons

containing 50% silicon and divided into a few types such as Kamosite, Stillprunite,
Gururite and Minnesotite.

9. Siderite Irons

containing 30% iron, yellow brownish in colours.

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14/7/2014

Iron production

steel production

carbon steel

alloy steel

cast iron

Iron production

steel production

carbon steel

alloy steel

cast iron

Height is about 30 metres, 10 metres in diameter

Which type of iron ore contains 65%

of iron and has chemical formula of
Fe2O3 ?

Blast furnace
Think critically 2.0

Hematite irons. Iron ores consist of iron

oxide or carbonate associated with
earthly impurities.

Upper bell

The outside of the furnace is

constructed of steel plates and
fire bricks are lined inside.
Wall or hearth at the bottom in
which molten iron collects prior to
its tapping.
Bosh is the widest part and its
diameter depends upon the
output.

Lower bell

Fire bricks
lining

Bosh
Tuyere

Hearth
Fig 2.2 Blast furnace

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Iron production

steel production

carbon steel

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alloy steel

cast iron

Iron production

Height is about 30 metres

alloy steel

Process:

Upper bell

1.After charging the furnace with raw

materials, a blast of hot air is passed
through the blast pipe and tuyere. At
the bottom of the furnace (hearth) a
high temperature of 1900C is
obtained. At this tempt. carbon
present acts as a reducing agent and
reacts on the ores as follows:
3Fe2O3 + C = 2Fe3O4 + CO
Fe3O4 + 4C = 3Fe + 4CO
CO thus formed reacts on the ores as
follows:
3Fe2O3 + CO = 2Fe3O4 + CO2
Fe3O4 + 4CO = 3Fe + 4CO2

Lower bell

Fire bricks
lining

Bosh

Lower bell

Fire bricks
lining

Bosh

Tuyere

Tuyere

Hearth

carbon steel

cast iron

Upper bell

2.The limestone acts as a flux assists

the melting of the metal and forms a
combination with the non-metallic
portions of the ore to form a metal
slag. The floating slag is removed
from time to time (2 hrs) and the
molten metal is tapped (4 hrs)
through the hole near the bottom.

Hearth

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steel production

carbon steel

Height is about 30 metres

Process:

Iron production

steel production

alloy steel

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cast iron

Iron production

steel production

carbon steel

alloy steel

cast iron

Advantages and Disadvantages

Advantages:

Disadvantages:

1. The larger, efficient furnaces

can produce hot metal at costs
competitive with other iron
making technologies.
2. Resultant slag is drawn off and
spun to form the rock wool
product (road making).
3. It can produce from 1,000 to
almost 10,000 tonnes of iron
daily.

1. Inevitable emissions of carbon

dioxide as iron is reduced from
iron oxides by carbon.
2. High in cost and capital for
operation.

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Steel is an alloy, mostly made up of iron and with a carbon content.

The principal methods of manufacturing of steel are:
a. Basis oxygen furnace (BOF)
b. Electric arc furnace (EAF)

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14/7/2014

Iron production

steel production

carbon steel

alloy steel

cast iron

Iron production

steel production

carbon steel

alloy steel

cast iron

Height is about 2 metres, 1.5 metres in diameter

Basis oxygen furnace (BOF)

It is a vertical cylindrical vessel
with a closed bottom and an
open upper cone through
which a water-cooled oxygen
lance can be raised and
lowered.
The vessel is lined with a
refractory such as magnesite
and is mounted on trunnions
so that it can be tilted for
charging and also for tapping
liquid steel.

Process:

Fig 2.3 Basis oxygen furnace

1. Molten blast furnace irons and 1/4 of

steel scrap are poured into the
furnace.
2. The furnace is then set upright and a
water-cooled lance with 99% pure
oxygen blows onto the charging
materials (high velocity). The
duration of the oxygen blow,
normally close to 20 minutes. Fluxes
(burnt lime) are fed into the vessel to
form slag, which absorbs impurities
of the steelmaking process.

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Iron production

steel production

carbon steel

alloy steel

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cast iron

Iron production

steel production

carbon steel

alloy steel

cast iron

Advantages and Disadvantages

Process:

Advantages:

Disadvantages:

3. The steel is then tapped into a

ladle at temperatures near to
1600C. The steel is further
refined in the ladle furnace, by
adding alloying materials to
give the steel special
properties required.
4. After the steel is removed from
the BOF vessel, the slag, filled
with impurities, is poured off
and cooled.

1. Pure oxygen is used instead of

air to oxidize the impurities and
prevent air pollution.
2. High production rates (30 to
360 tonnes of steel can be
produced in 30 to 45 min), less
labour, and steel with a low
nitrogen content.
3. Major by-product is carbon
monoxide, which can be used
as a fuel or in producing
various chemicals, such as
acetic acid.

1. High skill expertise is needed.

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Iron production

steel production

carbon steel

alloy steel

Why temperature of approximately

1600C is required in blowing
process for BOF ?
This helps to melt the scrap, lowers the
carbon content of the molten iron and
helps to remove unwanted chemical
elements.

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cast iron

Think critically 2.1

Iron production

steel production

carbon steel

Electric arc furnace (EAF)

The
electric-arc
furnace
employs three vertical graphite
or
amorphous
carbon
electrodes for producing arcs,
striking on to the charge and
heating it to the required
temperature.
As the electric-arc furnace
utilizes the external origin of
energy (electric current), it is
capable to melt up to 100% of
steel scrap.

alloy steel

cast iron

Fig 2.4 Electric arc furnace

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14/7/2014

Iron production

steel production

carbon steel

alloy steel

cast iron

Iron production

steel production

carbon steel

Process:

Process:

1. Charge materials which containing

steel scraps, iron ores, oxide irons
and limestones were added into the
furnace. Electric current flows to the
graphite electrodes to supply the
electric arc.
2. The electric arc will melt the oxidize
charged materials. Oxygen is blown
into the scraps, combusting the steel.
Only the graphite electrodes are
burning, therefore there is no metal
lost.

3. More slag formers are introduced and

more oxygen is blown into the bath,
burning out impurities such as silicon,
sulphur, phosphorus, aluminium,
manganese, and calcium, and
removing their oxides to the slag.
Removal of carbon takes place after
these elements have burnt out.
4. The steel is tapped out into a
preheated ladle through tilting the
furnace.

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Iron production

steel production

carbon steel

alloy steel

cast iron

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alloy steel

cast iron

Iron production

steel production

carbon steel

alloy steel

cast iron

Advantages and Disadvantages

Advantages:

Disadvantages:

1. It allows steel to be made from

a 100% scrap metal feedstock.
This greatly reduces the
energy required to make steel
when compared with primary
steelmaking from ores.
2. Purer product is obtained and
composition can be exactly
controlled during refining
process.
3. It makes 150 tonnes in each
melt, which takes around 90
min.

1. Heavy truck traffic for scrap,

materials handling, and
product.
2. Environmental effects of
electricity generation.
3. Higher cost and its use is
restricted to refining than
melting.

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Iron production

steel production

carbon steel

Why do graphite electrodes are more

prefered than amorphous carbon
electrodes?

Think critically 2.2

Graphite electrodes have double

conductivity and carry 2.5 times the
current than amorphous carbon
electrodes. The longer the arc, higher
the voltage required and less the input
of heat to the furnace. Thus, graphite
electrodes usually about 2/3 diameter
of amorphous carbon electrodes.
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alloy steel

cast iron

Crossword
Puzzle

2.

4.
1.

Cross
1. ___ iron is the oldest form of iron made by man.
3. ___ furnace is developed when a very high tempt. of
heated air is blasted inside.

3.
5.

Down
2. ___ iron is fundamentally an alloy which chief elements
are iron, silicon and carbon.
4. A high frequency furnace costs about 3 times as much to
install and able to produce an amount of purer product.
5. ___ is blown onto the charging materials with a very high
velocity to generate heat inside the furnace.
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