Laura.B+&&+Beth.R!!

· What are the main three raw materials used to make iron?  The three main materials are Iron ore, coke and limestone. · Where do the raw materials come from and how are they transported to the plant?  China and Brazil are the biggest producers of iron ore. China and USA are the biggest producers of coal. They are transported by ship and train · How and why are the raw materials processed before they are used in the blast furnace?  Iron oxides can come to the blast furnace plant in the form of raw ore, pellets or sinter. The raw ore is removed from the earth and sized into pieces that range from 0.5 to 1.5 inches. This ore is either Hematite (Fe2O3) or Magnetite (Fe3O4) and the iron content ranges from 50% to 70%.   · What role does each of these three raw materials play in the iron-making process?  Much is said nowadays about the consequences of human activity for the environment.  · <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif';">What can you say about the ecological effects of using these raw materials (for the country where they come from and for the means of transportation)? <span style="color: #ff33cc; font-family: 'Arial','sans-serif';"> There are great ecological problems. The materials need to be transported all over the world. This is done by ships and trains. This creates greenhouse gases and contributes to global warming. <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Symbol; mso-bidi-font-family: Arial;">· <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif';">How can the bad side effects be reduced? <span style="color: #ff33cc; font-family: 'Arial','sans-serif';"> They could offset what they do by planting trees to put carbon dioxide back into the atmosphere. They could also use more environmentally friendly fuels for the journey. · <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif';">Why is scrap used? <span style="color: #ff33cc; font-family: 'Arial','sans-serif';"> Scrap is used because it is cheap and easy to get hold of.
 * __<span style="font-size: 16pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif';">Corus Project Chapter 1 __**<span style="color: #ff33cc; font-family: 'Arial','sans-serif';">

<span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">during the converter process some elements in the hot metal react with oxygen (oxidize). The main elements involved are Fe (iron), C (carbon), Si (Silicon) and Mn (manganese). <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">
 * __<span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-bidi-font-size: 11.0pt;">Chapter two: Converter calculation: __**<span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">

<span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Fe-efficiency of converter process 98% (so 2% of the iron is oxidized during the process). <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Latent heat of steel 271 kJ/kg (energy necessary to melt 1 kg of steel). <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Heat capacity of steel 690 J/(kg °C) (energy needed to raise the temperature of the steel). <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Target temperature end of converter process 1650°C. <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Hot metal temperature 1350°C. <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Scrap temperature 20°C. <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Density liquid steel 7000 kg/m3 <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">suppose we have 100 kg of hot metal with the compositions as given above. <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Calculate the mass (kg) of each element. <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Fe – 94.9kg <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">C – 4.55kg <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Si – 0.25kg <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Mn – 0.3kg <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">In the converter process we make steel with the composition: Fe with 0.05 %C and 0.1% Mn. <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How many kg of each element are oxidized (take Fe-efficiency into account) of the 100 kg hot metal? <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Fe – 93.002kg <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">C – 4.459 <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Si – 0.245 <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Mn – 0.294 In the converter process we make steel with the composition: Fe with 0.05 %C and 0.1% Mn. <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How many kg of each element are oxidized (take Fe-efficiency into account) of the 100 kg hot metal? Fe – 93.002kg C – 4.459 Si – 0.245 Mn – 0.294 <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How many kg of steel are produced? 97.461kg <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Calculate the amount of energy that is generated during the process. From Fe: 4.3 X 1.898 = 8.1614 From C: 11.7 X 4.5 = 52.65 From Si: 33.9 X 0.25 = 8.475 From Mn: 7.4 X 0.2 = 1.48 Add all 4 figures to give total = 70.7664
 * || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">Composition of hot metal (%): <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">heat generation of oxidation (MJ/kg) <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">Fe <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">94.9 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">4.3 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">C <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">4.55 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">11.7 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">Si <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">0.25 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">33.9 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">Mn <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">0.3 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 14pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';">7.4 <span style="font-size: 12pt; color: #ff33cc; font-family: 'Times New Roman','serif'; mso-fareast-font-family: 'Times New Roman';"> ||

an average Dutch household uses 2000 m3 natural gas a year (for heating, cooking etc). Combustion of natural gas produces 32 MJ/m3. <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How much energy is used in natural gas a year per household? 32 X 2000= 64000 MJ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">The energy produced from how many kg of hot metal is equivalent to the energy used in natural gas of one household? 64000/70.7664= 904.4 kg

the combustions of Carbon generated carbon monoxide and carbon dioxide which leave the process as waste gasses. <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">If 45% of the heat generated by the C combustions will leave the process through the waste gasses what will be the temperature of the liquid steel? 2083.5 degrees Celsius <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">If we want to melt 1 kg of scrap and heat it to 1650°C how much energy is required? <span style="font-size: 16pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">1395700 / 1000 = 1395.7Kj <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How many kg of scrap can be melted with the 100 kg of hot metal making steel of 1650°C? <span style="font-size: 19.5pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">19.9kg <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How many kg of steel are produced? <span style="font-size: 19.5pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">113.1kg <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">If we want to make 320 tons of this steel how many tons of hot metal and scrap are required? <span style="font-size: 18.5pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">263 .7 tons of hot metal 56.3 tons of scrap <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">How many cubic meters of steel are that? <span style="font-size: 19.5pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">320 divided by 7 = 45.7m cubed <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: Wingdings; mso-bidi-font-family: Arial; mso-fareast-font-family: 'Times New Roman';">§ <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">Suppose a steel ladle has an internal diameter of 4 meters. What is the required height of the ladle if the steel surface must be 50 cm below the top of the ladle? <span style="font-size: 12pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">The surface of the bottom of the ladle is = pi r². Therefore: 3.1415 X 2² = 3.1415 X 4 = __12.56 cm squared.__ (bottom surface of ladle) The volume form our last question was 45.71m cubed. Height of cylinder = 45.71 / 12.56 = 3.69m cubed. Thus the height of the ladle must be 3.69m + 0.5m for spillage= 4.14 <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 19.5pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 14pt; color: #ff33cc; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">

After the converter process the steel is tapped into a steel ladle. At a secondary metallurgy installation the chemical composition is adapted to the required composition and temperature. After the converter process there is free oxygen in the steel still reacting with the remaining carbon generating carbon monoxide. Before steel can be cast the free oxygen has to be removed. This is done by adding Aluminium which reacts with oxygen to aluminium oxide. This is called ‘killing the steel’. The aluminium oxide is a solid and is formed as small particles in the steel. The very small particles (<= 1μm) do not harm the properties of the steel. Large particles will float out (the particles are lighter than steel). To make steel for beverage cans minimising the amount of these non-metallic particles (inclusions) above a critical size is very important.