Step 1: Concentration of ore
- The Ore is crushed in the crushers and it is broken up into smaller pieces. It is concentrated with gravity separation process in which it is washed with water to remove clay, sand, ETC.
Step 2: Calcination
- The Ore is then heated without the presence of air ( calcined ) During calcinations, moisture is removed and impurites such as sulphur. It will change into Sulphur dioxide as this process causes carbon to decompose and turn into oxide.
Step 3: Smelting
- The concentrated ore is mixed with a specific amount of coke and limestones. The mixture is then transfered into the blast furnace from the top.
Reactions in the Blast Furnace!
Reaction 1 : Formation of carbon monoxide
- Coke burns in air to form Carbon Dioxide and it produces lots of heat. This process takes place near the bottom of the furnace. The temperature will reach around 1875K. The carbon dioxide reacts further with coke and it will be reduced to CO.
Reaction 2 : Reduction oh Haematite to Iron
- The temperature in the upper part of the furnace is between 975K to 1075K. Haematite is reduced to Iron by CO here. The molten iron is then collected at the bottom of the furnace.
Process Flow Chart!
Information from : http://www.slideshare.net/sarbjitarora/extraction-of-iron
Pictures from : http://i632.photobucket.com/albums/uu42/ecknotts/Picture10.png , http://www.zimbio.com/Business+Development+Tips/articles/mAvmI1aG6Ll/Iron+ore+mining+process+flow+chart
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