Long1

Good afternoon gentlemen. You are now embarking on what is sure to be a fantastic international project that will provide you with skills essential to employment.
 * Longfield gp1

To begin, we will read our project pack and begin our investigations.

Best of luck, Mr Conway

PS this website explains what a wiki actually is:** http://www.commoncraft.com/video-wikis-plain-english

Their email addresses are:** Tom.vanEssen@corusgroup.com or Andy.McGee@corusgroup.com.
 * If you come across a particularly difficult part in the steelmaking process, one of the Corus engineers may be able to help.


 * Some useful links to find information on iron, steel and can making:**

http://www.corusgroup.com/en/responsibility/education/learning_zone/

http://www.ball-europe.com/ **products about the beverage can.** · What are the main three raw materials used to make iron? iron ore, limestone and coal. · Where do the raw materials come from and how are they transported to the plant? Raw materials are found underground and they are transported by a train. · How and why are the raw materials processed before they are used in the blast furnace? The raw materials are processed to give them the required properties for the blast furnace process. · What role does each of these three raw materials play in the iron-making process? During ironmaking, iron ore, coke, heated air and limestone or other fluxes are fed into a blast furnace. The heated air causes the coke combustion, which provides the heat and carbon sources for iron production. Limestone or other fluxes may be added to react with and remove the acidic impurities, called slag, from the molten iron. The limestone-impurities mixtures float to the top of the molten iron and are skimmed off after melting is complete.** //**(Is this randomly found on a site called** http://www.wmrc.uiuc.edu/info/library_docs/manuals/primmetals/chapter2.htm? DK)//
 * Questions for Monday:

=Iron and steel making.= = = why is scrap used ? scrap is used because it is like recycling metal to be used again what are the advantages and disadvantages of using scrap, in the steel making process? Advantage: It is recycling old steel to help make new steel in corus. Using scrap metals is good for corus as they dont use the raw materials all the time cause they are using steel that they have made before. Disadvantage : The scrap could have other materials on it, so it can not be recycled. It is exspensive to recycle scrap.

chapter 3 part2: casting strands

=  •  We can cast 2 strands of steel at once. • These are 225mm thick and 1300mm wide. • We can cast them at 1.5m/ min. • This means in 1 minute our slab would be:  •  0.225 thick X 1.3 wide X 1.5 long (m)  •  So the volume would be: __0.43875__ Its mass is 7000Kg / m cubed, so its mass would be 7000 X ? (your answer from above) answer  = 3071.25 3071.25 x 2 = 6142.5 • So in 1 minute it makes 6.1 tons. • How much can we make operating at 90% of the year? • 6.1 X 60 = __366__ tones per hour X 24 hours X 365 days = __3206160__ • But only operates 90% of time so times answer by 0.9! • à ___2885544__  __•__  •  Why is it important cast is clean? It is important to keep the cast clean so it doesent become weaker than if it was clean. • Which inclusion is worst- one that keeps it’s shape or one rolled out? Explain your answer. rolled out because it would become longer than if it kept its shape. =

How much energy is needed to melt 1kg of scrap and then heat to 1650 degrees?

Start temp of scrap is 20 degrees. This means we need to heat it by 1650 - 20= 1630 degrees. The energy required to heat 1kg of steel by 1 degree is 690j. So, 1630 x 690 = 1124700joules of energy is required to heat the scrap. But in doing this, we also need to take it through its melting point and turn it into a luquid. This needs more energy again! Latent heat (energy needed to melt 1kg)= 27kj=271000j/kg. Now we add the energy needed to heat it and the energy needed to melt it: 1124700 + 271000= 1395700j is needed to heat and melt 1kg of scrap! 1395700/1000=1395.7kj

How many kg of scrap can be melted with 100kg of hot metal if we need the temperture to be 1650 degrees?

The total energy generated was 70.76mj But remember we lost around 23mj of energy when the hot gasses of carbon dioxide escaped so the remaining energy is: 70.76-23.69= 47.07mj of energy left in mixture. 47.07-19.28(energy used) =27.79mj now we need to divide this by the energy needed to melt 1kg of scrap= 1.39mj(if our last calculation for melting scrap was correct) So 27.79/1.39=19.9kg of scrap can be added and melted in the reaction.

How many kg of steel can we produce if we did this?

well, from our 100kg hot metal mixture we can make 93.2kg of steel(remember the rest is oxidised). And we can add 19.9kg of scrap to thid,so.93.2+19.9=113.1kg of steel!

If someone wanted us to make 320 tons of steel, hot many tons of hot metal and scrap are required?

we can make 113.1 kg of steel from 100kg mixture and 19.9kg of scrap so: 320/113.1=2.829x93.2=263.7 tons of hot metal needed 320/113.1=2.829x19.9=56.3 tons of scrap needed. CHECK WORKING:263.7+56.3=320 tons

How many cubic metres will 320 tons take up?

320 tons has a density of 7000kg/ m cubed. There is 1000kg in 1 ton. So the mass of the steel is 7 ton/ metre cubed. Volume = 320/7 = 45.7m cubed

A steel ladle has an internal diameter of 4m. What must we make the height of the ladle if we want the surface of the steel mixture to be 50cm(0.5m) below the height of it?

For this we are assuming the ladle is a cylinder shape - not a dish shape. The surface of the bottom of the ladle is = pi r sqaured. So:3.1415x(4/2) sqaured = 3.1415 x 2 sqaured = 3.1415 x 4 = 12.56cm sqaured.(bottom surface of ladle) The volume from our last question was 45.71m cubed. height of cylinder = 45.71/12.56 = 3.69m cubed. So the height of the ladle must be 3.69m + 0.5m for spillage = 4.14m.

How much energy is needed to melt 1kg of scrap and then heat to 1650 degrees?

Start temp of scrap is 20 degrees. This means we need to heat it by 1650 - 20= 1630 degrees. The energy required to heat 1kg of steel by 1 degree is 690j. So, 1630 x 690 = 1124700joules of energy is required to heat the scrap. But in doing this, we also need to take it through its melting point and turn it into a luquid. This needs more energy again! Latent heat (energy needed to melt 1kg)= 27kj=271000j/kg. Now we add the energy needed to heat it and the energy needed to melt it: 1124700 + 271000= 1395700j is needed to heat and melt 1kg of scrap! 1395700/1000=1395.7kj

How many kg of scrap can be melted with 100kg of hot metal if we need the temperture to be 1650 degrees?

The total energy generated was 70.76mj But remember we lost around 23mj of energy when the hot gasses of carbon dioxide escaped so the remaining energy is: 70.76-23.69= 47.07mj of energy left in mixture. 47.07-19.28(energy used) =27.79mj now we need to divide this by the energy needed to melt 1kg of scrap= 1.39mj(if our last calculation for melting scrap was correct) So 27.79/1.39=19.9kg of scrap can be added and melted in the reaction.

How many kg of steel can we produce if we did this?

well, from our 100kg hot metal mixture we can make 93.2kg of steel(remember the rest is oxidised). And we can add 19.9kg of scrap to thid,so.93.2+19.9=113.1kg of steel!

If someone wanted us to make 320 tons of steel, hot many tons of hot metal and scrap are required?

we can make 113.1 kg of steel from 100kg mixture and 19.9kg of scrap so: 320/113.1=2.829x93.2=263.7 tons of hot metal needed 320/113.1=2.829x19.9=56.3 tons of scrap needed. CHECK WORKING:263.7+56.3=320 tons

How many cubic metres will 320 tons take up?

320 tons has a density of 7000kg/ m cubed. There is 1000kg in 1 ton. So the mass of the steel is 7 ton/ metre cubed. Volume = 320/7 = 45.7m cubed

A steel ladle has an internal diameter of 4m. What must we make the height of the ladle if we want the surface of the steel mixture to be 50cm(0.5m) below the height of it?

For this we are assuming the ladle is a cylinder shape - not a dish shape. The surface of the bottom of the ladle is = pi r sqaured. So:3.1415x(4/2) sqaured = 3.1415 x 2 sqaured = 3.1415 x 4 = 12.56cm sqaured.(bottom surface of ladle) The volume from our last question was 45.71m cubed. height of cylinder = 45.71/12.56 = 3.69m cubed. So the height of the ladle must be 3.69m + 0.5m for spillage = 4.14m.