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http://en.wikipedia.org/wiki/Blast_furnace
13 June 2011
Fuel mixes together with air to produce metal. Have a look at this website
13 June 2011
In the Blast furnace, reduction of iron oxides takes place in different
temperature ranges. Hot air is blown from the bottom of the furnace
and coke is burnt to give temperature upto about 2200K in the lower
portion itself. The burning of coke therefore supplies most of the heat
required in the process. The CO and heat moves to upper part of the
furnace. In upper part, the temperature is lower and the iron oxides
(Fe2O3 and Fe3O4) coming from the top are reduced in steps to FeO.
Thus, the reduction reactions taking place in the lower temperature
range and in the higher temperature range, depend on the points of
corresponding intersections in the ΔrG0 vs T plots. These reactions can
be summarised as follows:
At 500 – 800 K (lower temperature range in the blast furnace) :
14 June 2011
3 Fe2O3 + CO → 2 Fe3O4 + CO2
Fe3O4 + 4 CO → 3Fe + 4 CO2
Fe2O3 + CO → 2FeO + CO2 At 900 – 1500 K (higher temperature range in the blast
furnace):
C + CO2 → 2 CO
FeO + CO → Fe + CO2
Limestone is also decomposed to CaO
which removes silicate impurity of the ore
as slag. The slag is in molten state and
separates out from iron.
The iron obtained from Blast furnace
contains about 4% carbon and many
impurities in smaller amount (e.g., S, P, Si,
Mn). This is known as pig iron and cast into
variety of shapes. Cast iron is different from
pig iron and is made by melting pig iron
with scrap iron and coke using hot air blast.
It has slightly lower carbon content (about
3%) and is extremely hard and brittle.
Further Reductions
Wrought iron or malleable iron is the
purest form of commercial iron and is
prepared from cast iron by oxidising impurities in a
reverberatory furnace lined with haematite. This
haematite oxidises carbon to carbon monoxide:
Fe2O3 + 3 C → 2 Fe + 3 CO (6.33)
Limestone is added as a flux and sulphur, silicon
and phosphorus are oxidised and passed into the slag. The metal is
removed and freed from the slag by passing through rollers.
14 June 2011
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