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Tutorial No.1
Iron making
Eng. Hany Khalifa
Supervisor : Prof. Dr. Mohamed Taha
Iron Ore
Iron Ore is the 4th. Element available in the earth crest
after Oxygen, Silicon and Aluminum.
2
Steps of metal extraction
Geological Surveying
Ore sources
Mining
Ore
Gangue Processing
Tailings Concentration
Concentrate
Slag Extraction
Alloying Addition
Fabrication
Metal
3
How is Steel made-I
How is Steel made-II
How is Steel made-III
Blast furnace
What is a Blast Furnace?
The purpose of a blast furnace is
to reduce and convert iron oxides
into liquid iron called "hot metal".
The blast furnace is a huge, steel
stack lined with refractory brick.
Iron ore, coke and limestone are
put into the top, and preheated air
is blown into the bottom.
The Method
Three substances are needed to enable to extraction of
iron from its ore. The combined mixture is called the
Iron ore, haematite - often contains sand with iron oxide,
Fe2O3.
Limestone (calcium carbonate).
Coke - mainly carbon
The charge is placed a giant chimney called a
The blast furnace is around 30 metres high and lined with
fireproof bricks. Hot air is blasted through the bottom.
Several reactions take place before the iron is
finally produced...
Oxygen in the air reacts with coke to give carbon dioxide:
C(s) + O 2(g) CO2(g)
Oxygen with iron must be firstly removed, because steel production is based
in metallic iron and Carbon, and not in Hematite and Magnetite. If it were
removed in the electric furnace, This process would be, besides
impractical, quite expensive
Direct reduction
In a direct reduction process, Oxygen is removed from the iron oxides
contained in the iron ore by reducing gases action. Reduction is
accomplished until some degree around 96 % but not completely.
Iron ore is reduced directly, without melting it and the product obtained is a
porous metallized solid known as Direct Reduced Iron (DRI), if this product
is briquetted at high temperature, greater 650C the product is known as
Hot Briquetted Iron (HBI).
Methods of DR producing
1. Coal based processes
2. Gas based processes
1-Carburization with CO
2-Carburization with CH4
1-Carburizing with CO
Studies of reaction kinetics are shown that these reactions have a better
yield from 500 C to 700 C due to a higher reaction velocity at this
temperature range.
2-Carburization with CH4