This process reduces the iron ore to liquid iron. Step 3: Steelmaking. The molten iron from the blast furnace is transferred to a basic oxygen furnace (BOF) or an electric arc furnace (EAF). In the BOF, oxygen is blown through the molten iron to remove carbon and other impurities. ... An efficient steel manufacturing process flow diagram not ...

The raw materials for the acid process are of a siliceous nature, but low in sulfur and phosphorus. The maintenance of an acid slag prevents the elimination of these elements. The pig iron and scrap are charged, and when melted the slag is rendered fluid and oxidized by iron-ore additions.

Throat: zone for charging the burden [ferric charge + reductant (coke)].The blast furnace gases circulate through the throat of the furnace toward the dry and wet cleaning systems. The temperature in the throat is 200–250 °C, the pressure is around 1.5 atm (there are blast furnaces in Russia and other countries that operate with bigger excesses of pressure), …

As mentioned earlier iron ore smelting process is needed to be performed to improve the efficiency of the furnace and to work economically. It is done by removing unwanted materials and by improving the density of lumps, size, or richness. Iron Smelting in Blast Furnace. Iron smelting involves two main processes in the blast furnace:

The metallic iron in this process is produced by the reduction of iron oxide below the fusion temperature of iron ore (1535 deg C) by utilizing carbonaceous material present in the non-coking coal. As the iron ore is in direct contact with the reducing agent throughout the reduction process, it is often termed as direct reduced iron (DRI).

Iron processing, use of a smelting process to turn the ore into a form from which products can be fashioned. Included in this article also is a discussion of the mining of iron and of its preparation for smelting. Iron (Fe) is a relatively dense …

diagram of the iron and steel industry in Figure 12.5-1. Coke production is discussed in detail in Section 12.2 of this publication, and more information on the handling and transport of materials is found in Chapter 13. 12.5.1.1 Sinter Production - The sintering process converts fine-sized raw materials, including iron ore, coke breeze,

In the blast furnace, the iron ore reacts with the carbon contained in the coke to form grey or white pig iron. Combustion process. The iron in the processed ores must be dissolved out by chemical processes. This requires an …

Molten iron is produced in a blast furnace by the following steps: 1. Charge (solid iron ore, coke, and limestone) is constantly dumped into the top of the furnace. 2. A blast of hot air is blown into the furnace from the bottom. 3. Coke is the fuel that supplies additional heat, increasing the temperature of the charge. 4.

A useful diagram to describe the thermodynamics of iron oxide reduction is the Baur–Glässner diagram, which is shown in Figure 2. The diagram displays the stability areas of different iron oxide phases depending on the temperature and gas oxidation degree (GOD). ... During reduction of a porous iron ore particle, the following process steps ...

The main stages of the steel making process flow chart include iron ore extraction and processing, smelting in a blast furnace or electric arc furnace, primary steelmaking in a basic oxygen furnace or through electric arc …

In the blast furnace process, iron-bearing materials (e.g. lumps iron ore, sinter/pellets, mill scale and steelmaking slag), coke (fuel as well as reducer) and flux (limestone and/or dolomite) are charged by the skip car or conveyor belt from the top of the furnace. ... iron ore should be present in the areas of maximum gas flow for efficient ...

Processing of the ore ranges from simple crushing and screening to a standard size, through to processes that beneficiate or upgrade the quality of the iron ore products. This is done by …

remove oxygen from the iron oxide in the iron ore. Diagram of a Blast Furnace . Smelting of Iron: Chemical Equations The coke burns: C + O 2 CO 2 ... replaced fairly often as the carbon is used up in the process. The bauxite or alumina is usually dissolved in a cryolite solution formed from synthetic sodium aluminium fluoride, which means

The iron-bearing components in the charge to the furnace are the simple oxides of iron, Fe2O3, and Fe3O4. The natural ore normally are hematite (Fe2O3) or magnetite (Fe3O4). Pellets are principally Fe2O3. Iron ore sinter can range in composition from Fe2O3 and Fe3O4 to fused mixtures containing magnetite, fayalite, 2FeO.SiO2, and di-calcium ...

The steel making process flow diagram illustrates this journey in a clear and structured manner. It typically begins with the extraction of iron from the ore through reduction processes in a blast furnace or direct reduction routes.

The smelting process of blast furnace is carried out in the shaft furnace of a closed countercurrent reactor and heat exchanger. The complex physical changes and chemical reactions are completed in the process of the countercurrent movement of the charge and gas in which the raw materials containing iron oxide (sinter, pellets, etc.), coke, slag flux (limestone) …

Use our notes to learn what an ore is in IGCSE chemistry. Understand how a metal is extracted relative to its position in the reactivity series. ... copper, iron oxide and aluminium oxide. Useful metals are often ... In many cases the ore is an oxide of the metal, therefore the extraction of these metals is a reduction process since oxygen is ...

Blast furnace uses iron ore as the iron-bearing raw materials, and coke and pulverized coal as reducing agents and heat source, lime, or limestone as the fluxing agents. ... Blast furnace process: 1—iron burden, 2—flux and/or other additives, 3—coke, 4—hot blast with oxygen, 5—injectants, 6—taping of hot metal and slag, 7—top gas ...

In addition to the process route via the blast furnace process, there is another option for extracting crude steel from iron ores using the so-called direct reduced iron (DRI) process (secondary route). The starting point for the efforts to find an alternative to the blast furnace process was the relatively high process expenditure.

1 Schematic diagram of blast furnace ironmaking. 2 Raw materials: iron ore, solvent, fuel. 2.1 Iron ore. 2.2 solvent. 2.3 Fuel. 3 Combustion of fuel. ... monoxide and hydrogen generated by the combustion of carbon in coke and …

The iron ore production has significantly expanded in recent years, owing to increasing steel demands in developing countries. However, the content of iron in ore deposits has deteriorated and low-grade iron ore has been processed. The fines resulting from the concentration process must be agglomerated for use in iron and steelmaking. This chapter …

Diagram showing the carbon extraction of iron. The raw materials: iron ore (hematite), coke (an impure form of carbon), and limestone are added into the top of the blast furnace. Hot air is blown into the bottom. Zone 1. Coke …

ore chosen for the D R process, the tota l iron content should be as high as pos sible and the gangue conte nt should not only be a minimum, bu t the gangue should

The first step in the production of steel or cast iron alloys is the reduction of iron ore, which contains iron oxide and gangue or mineral impurities, to unrefined hot metal or pig iron. ... Ellington diagrams (Figure 3) can help …

A simplified diagram of a Blast Furnace is drawn below. A typical blast furnace may be up to 32 metres in height and 10 metres in diameter. They have thick steel sides, lined with refractory bricks, to ensure that heat is not lost. ... As the mixture of iron ore, coke and limestone heats, the hot waste gases are collected and cleansed. They are ...

After being removed from the mine, i.e. after the iron ore mining process, iron ore must go through several processing iron ore steps. Now that we are understanding ‘what is iron ore?’ and learning more about iron ore, let's start first with knowing the procedure for processing iron ore. What Is Iron Ore Processing? Screening ...

The process of extracting iron ore involves mining, where large-scale excavation is carried out to access the ore deposits deep within the earth. Once the iron ore is extracted, it undergoes a series of processing steps to remove impurities and prepare it for further use. The first step in this process is crushing and grinding the ore to a fine ...

Iron ore processing is a complex and vital process that transforms raw iron ore into usable steel. From exploration and extraction to grinding, beneficiation, and ironmaking, each stage plays a crucial role in producing …

The Midrex® and Energiron gas-based processes use predominantly iron ore pellets as feedstock, but sometimes with inclusion of lump ore in the furnace charge. The Circored and Finmet / Finored gas-based processes utilize iron ore fines as feedstock.The SLRN coal-based rotary kiln process uses lump ore and, increasingly, pellets as feedstock.