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· What are the main three raw materials used to make iron? 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. · 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)? 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. · How can the bad side effects be reduced? 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. · Why is scrap used? Scrap is used because it is cheap and easy to get hold of.
 * __ Corus Project Chapter 1 __**

· What are the advantages and disadvantages of using scrap in the steel making process? Advantages- The Basic Oxygen Furnace uses scrap metal because it is easier, cheaper and recycles scrap metal. Using scrap is much cheaper and new metal does not have to be produced- cutting down on pollution from production. Disadvantages- The metal isn’t as strong as it would be if it was new; because it has already been used.

**__ Chapter 2 __** During the converter process some elements in the hot metal react with oxygen (oxidise). The main elements involved are Fe (iron), C (carbon), Si (Silicon) and Mn (manganese). Fe-efficiency of converter process 98% (so 2% of the iron is oxidised during the process). Latent heat of steel 271 kJ/kg (energy necessary to melt 1 kg of steel). Heat capacity of steel 690 J/(kg °C) (energy needed to raise the temperature of the steel). Target temperature end of converter process 1650°C. Hot metal temperature 1350°C. Scrap temperature 20°C. Density liquid steel 7000 kg/m3
 * __ Chapter two: Converter calculation __**
 * || Composition of hot metal (%): || heat generation of oxidation (MJ/kg) ||
 * Fe || 94.9 || 4.3 ||
 * C || 4.55 || 11.7 ||
 * Si || 0.25 || 33.9 ||
 * Mn || 0.3 || 7.4 ||

Suppose we have 100 kg of hot metal with the compositions as given above. § Calculate the mass (kg) of each element. Fe – 94.9kg C – 4.55kg Si – 0.25kg Mn – 0.3kg

In the converter process we make steel with the composition: Fe with 0.05 %C and 0.1% Mn. § How many kg of each element are oxidised (take Fe-efficiency into account) of the 100 kg hot metal? Fe – 93.002kg C – 4.459 Si – 0.245 Mn – 0.294 § How many kg of steel are produced? 97.461kg § 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

An average Dutch household uses 2000 m3 natural gas a year (for heating, cooking etc). Combustion of natural gas produces 32 MJ/m3. § How much energy is used in natural gas a year per household? 32 X 2000= 64000 MJ § 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. § 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 § If we want to melt 1 kg of scrap and heat it to 1650°C how much energy is required?  1395700 / 1000 = 1395.7Kj § How many kg of scrap can be melted with the 100 kg of hot metal making steel of 1650°C? 19.9kg § How many kg of steel are produced? 113.1kg § If we want to make 320 tons of this steel how many tons of hot metal and scrap are required? 263 .7 tons of hot metal 56.3 tons of scrap § How many cubic meters of steel are that? 320 divided by 7 = 45.7m cubed § 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? 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 We got stuck and used the powerpoint for help 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.

__Chapter 3

Chapter 4: Can making & recycling__
 * 1) The raw materials are extracted and are then transported to iron production factory.
 * 2) The materials are produced into steel.
 * 3) The iron is then converted into a steel roll.
 * 4) This can then be transported to the coke can production site, where it is then roled out, cut into precise circles, then punched or pressed in a mould.
 * 5) The cans are then disinfected and filled with coca-cola.
 * 6) Finally the lid/top is placed on the top securely.

