Casting Furnaces Summary
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The blast furnace document describes several common methods for producing steel from iron ore. The blast furnace uses iron ore, coke and limestone as raw materials. Hot air is blown into the bottom of the furnace to produce liquid iron and slag. The bessemer converter and basic oxygen furnace then refine the liquid iron into steel by injecting oxygen to lower the carbon content. Additional furnaces like the open hearth furnace use fuel to generate heat and melt scrap metal, while the electric arc furnace uses an electric current to melt scrap. The vacuum induction furnace produces very high quality steel by melting metal in a vacuum to remove gaseous impurities.
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![Method :
The carbon monoxide reduces the iron in the ore to give molten iron:
2(g)+ 3CO(l)2Fe3(s)O2+ Fe(g)3CO
The limestone from 2, reacts with the sand to form slag (calcium silicate):
3(l)CaSiO(s)+ SiO(s)CaO
Hot air drives the reaction
Bessemer Convertor
Charge : Melted high carbon iron (pig iron)
+ bottom injected air
Products : Liquid steel product
Method : Fast reaction:
}} [Fe] + {CO2C] + {O-[Fe
Minor reaction
} (FeO)2[Fe] + {O
: 鏈鏤鏈鏤鏈鏤эlining (acidic)2SiO
Basic-Oxygen Furnace
Charge : Melted pig iron and scrap are poured (charged) into a vessel.
Fluxing agents are added, like limestone.](https://image.slidesharecdn.com/5a970373-d348-48dd-a326-b99dfd622488-160809134823/85/Casting-Furnaces-Summary-2-320.jpg)
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Casting Furnaces Summary
- 1. Blast Furnace Charge : Iron ore, coke and limestone are put into the top, and preheated air is blown into the bottom. .3O2ften contains sand with iron oxide, Feo-Iron ore, haematite Limestone (calcium carbonate). Coke - mainly carbon Products : liquid iron called "hot metal" pig iron Fe with 4% C, 0.4% Si, 0.3% Mn, 0.025% S, and up to 1.5% P Too impure to be of commercial use : 鏈鏤鏈鏤鏈鏤эfireproof bricks
- 2. Method : The carbon monoxide reduces the iron in the ore to give molten iron: 2(g)+ 3CO(l)2Fe3(s)O2+ Fe(g)3CO The limestone from 2, reacts with the sand to form slag (calcium silicate): 3(l)CaSiO(s)+ SiO(s)CaO Hot air drives the reaction Bessemer Convertor Charge : Melted high carbon iron (pig iron) + bottom injected air Products : Liquid steel product Method : Fast reaction: }} [Fe] + {CO2C] + {O-[Fe Minor reaction } (FeO)2[Fe] + {O : 鏈鏤鏈鏤鏈鏤эlining (acidic)2SiO Basic-Oxygen Furnace Charge : Melted pig iron and scrap are poured (charged) into a vessel. Fluxing agents are added, like limestone.
- 3. Product : Higher steel quality than open hearth. Used to make plate, sheet, I-beam, tubing and channel. Method : The molten metal is blasted with pure oxygen. This produces iron oxide which then reacts with carbon to produce CO and CO2. The slag floats to the top of the metal. : 鏈鏤鏈鏤鏈鏤эrefractory bricks Open-Hearth Furnace Charge : Pig Iron and scrap supplied by oil or gas Products: molten metal and slag
- 4. Method: uses fuel to generate heat, and melt metal. Electric Furnace Charge : Graded steel scrap Products : Can produce 60-90 tons of steel per day Highly alloyed steel , stainless steel , heat resisting , high speed steels . Steel is higher quality than open-hearth and BOF Method : Uses electric arc from electrode to metal to heat and melt it . Vacuum Furnace 鏈鏤鏈わ 鏤鏈鏤モ Method : Uses induction furnaces. Air is removed from the furnace, this removes the gaseous impurities from the molten metal. Products : very high-quality steel