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Coke is a grey, hard, and porous coal-based fuel with a high carbon content. It is made by heating coal or oil in the absence of air. Coke is an important industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges.
Wrought iron is an iron alloy with a very low carbon content in contrast to that of cast iron. It is a semi-fused mass of iron with fibrous slag inclusions, which give it a wood-like "grain" that is visible when it is etched, rusted, or bent to failure. Wrought iron is tough, malleable, ductile, corrosion resistant, and easily forge welded, but is more difficult to weld electrically.
Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its carbon appears: white cast iron has its carbon combined into an iron carbide named cementite, which is very hard, but brittle, as it allows cracks to pass straight through; grey cast iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material breaks, and ductile cast iron has spherical graphite "nodules" which stop the crack from further progressing.
Steelmaking is the process of producing steel from iron ore and/or scrap. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel.
Slag is a by-product of smelting (pyrometallurgical) ores and recycled metals. Slag is mainly a mixture of metal oxides and silicon dioxide. Broadly, it can be classified as ferrous, ferroalloy or non-ferrous/base metals. Within these general categories, slags can be further categorized by their precursor and processing conditions. "Slag generated from the EAF process can contain toxic metals, which can be hazardous to human and environmental health".
A blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. Blast refers to the combustion air being supplied above atmospheric pressure.
Industrial processes are procedures involving chemical, physical, electrical, or mechanical steps to aid in the manufacturing of an item or items, usually carried out on a very large scale. Industrial processes are the key components of heavy industry.
Ferrochrome or ferrochromium (FeCr) is a type of ferroalloy, that is, an alloy of chromium and iron, generally containing 50 to 70% chromium by weight.
Coking is the heating of coal in the absence of oxygen to a temperature above 600 °C (1,112 °F) to drive off the volatile components of the raw coal, leaving a hard, strong, porous material of high carbon content called coke. Coke is almost all carbon. The porosity gives it a high surface area, which makes it burn faster. When a kilogram of coke is burned it releases more heat than a kilogram of the original coal.
Puddling is the process of converting pig iron to bar (wrought) iron in a coal fired reverberatory furnace. It was developed in England during the 1780s. The molten pig iron was stirred in a reverberatory furnace, in an oxidizing environment to burn the carbon, resulting in wrought iron. It was one of the most important processes for making the first appreciable volumes of valuable and useful bar iron without the use of charcoal. Eventually, the furnace would be used to make small quantities of specialty steels.
Wheeling-Pittsburgh Steel was a steel manufacturer based in Wheeling, West Virginia.
Coal analysis techniques are specific analytical methods designed to measure the particular physical and chemical properties of coals. These methods are used primarily to determine the suitability of coal for coking, power generation or for iron ore smelting in the manufacture of steel.
Ground granulated blast-furnace slag is obtained by quenching molten iron slag from a blast furnace in water or steam, to produce a glassy, granular product that is then dried and ground into a fine powder. Ground granulated blast furnace slag is a latent hydraulic binder forming calcium silicate hydrates (C-S-H) after contact with water. It is a strength-enhancing compound improving the durability of concrete. It is a component of metallurgic cement. Its main advantage is its slow release of hydration heat, allowing limitation of the temperature increase in massive concrete components and structures during cement setting and concrete curing, or to cast concrete during hot summer.
Cornwall Iron Furnace is a designated National Historic Landmark that is administered by the Pennsylvania Historical and Museum Commission in Cornwall, Lebanon County, Pennsylvania in the United States. The furnace was a leading Pennsylvania iron producer from 1742 until it was shut down in 1883. The furnaces, support buildings and surrounding community have been preserved as a historical site and museum, providing a glimpse into Lebanon County's industrial past. The site is the only intact charcoal-burning iron blast furnace in its original plantation in the western hemisphere. Established by Peter Grubb in 1742, Cornwall Furnace was operated during the Revolution by his sons Curtis and Peter Jr. who were major arms providers to George Washington. Robert Coleman acquired Cornwall Furnace after the Revolution and became Pennsylvania's first millionaire. Ownership of the furnace and its surroundings was transferred to the Commonwealth of Pennsylvania in 1932.
Loss on ignition (LOI) is a test used in inorganic analytical chemistry and soil science, particularly in the analysis of minerals and the chemical makeup of soil. It consists of strongly heating ("igniting") a sample of the material at a specified temperature, allowing volatile substances to escape, until its mass ceases to change. This may be done in air or in some other reactive or inert atmosphere. The simple test typically consists of placing a few grams of the material in a tared, pre-ignited crucible and determining its mass, placing it in a temperature-controlled furnace for a set time, cooling it in a controlled atmosphere, and re-determining the mass. The process may be repeated to show that the mass change is complete. A variant of the test in which mass change is continually monitored as the temperature changes is called thermogravimetry.
A cupola or cupola furnace is a melting device used in foundries that can be used to melt cast iron, Ni-resist iron and some bronzes. The cupola can be made almost any practical size. The size of a cupola is expressed in diameters and can range from 1.5 to 13 feet. The overall shape is cylindrical and the equipment is arranged vertically, usually supported by four legs. The overall look is similar to a large smokestack.
The HIsarna ironmaking process is a direct reduced iron process for iron making in which iron ore is processed almost directly into liquid iron (pig iron). The process combines two process units, the Cyclone Converter Furnace (CCF) for ore melting and pre-reduction and a Smelting Reduction Vessel (SRV) where the final reduction stage to liquid iron takes place. The process does not require the manufacturing of iron ore agglomerates such as pellets and sinter, nor the production of coke, which are necessary for the blast furnace process. Without these steps, the HIsarna process is more energy-efficient and has a lower carbon footprint than traditional ironmaking processes. In 2018 Tata Steel announced it has demonstrated that more than 50% CO2 emission reduction is possible with HIsarna technology, without the need for carbon capture technology.
Sinter plants agglomerate iron ore fines (dust) with other fine materials at high temperature, to create a product that can be used in a blast furnace. The final product, a sinter, is a small, irregular nodule of iron mixed with small amounts of other minerals. The process, called sintering, causes the constituent materials to fuse to make a single porous mass with little change in the chemical properties of the ingredients. The purpose of sinter are to be used converting iron into steel.
A metallurgical furnace, often simply referred to as a furnace when the context is known, is an industrial furnace used to heat, melt, or otherwise process metals. Furnaces have been a central piece of equipment throughout the history of metallurgy; processing metals with heat is even its own engineering specialty known as pyrometallurgy.
Agglomerate is a material composed of iron oxides and gangue, roasted and sintered in an agglomeration plant. This product is obtained by burning coal previously mixed with iron ore and oxides. This conditioning of iron ore optimizes its use in the blast furnace.
References
- ↑ "Metallurgical Coke or Blast Furnace Coke for iron and steel industry". Archived from the original on 2011-07-08. Retrieved 2011-02-11.
- ↑ Reifensteinin (2003) ACARP Report C12004 Coke Reactivity Test: Critical Parameters
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