Andrew+James+Kingsley

__ Coke To Coke – Chapter 1 __ - The three main ingredients in Iron are Iron Ore, Coke and Limestone (to remove impurities). As well as these, gases such as Oxygen.

- Iron ore comes primarily from three countries: China, Brazil and Australia. These countries produce a combined total of 990 Million Metric tons. I can’t find the largest producers of Limestone but one the largest producers of coke (coal) are right here in Britain. All these commodities are transported by trucks and huge transport ships.

- Iron ore is processed while in the blast furnace with the limestone, as the limestone removes impurities which would damage the strength of the finished Steel.

- In the iron smelting process each product has its own use. The Iron ore is iron, but surrounded by impurities which need to be separated off, as only the iron is needed. The Limestone is used to make the impurities have a lower melting point, and they will melt away from the iron that is needed. The coke is needed to make the furnace burn at a higher heat.

- The ecological effects of using all the raw materials are quite bad. A lot of the raw materials have to be transported from faraway places such as China or India. The ecological damage of transporting millions of tonnes of raw materials across the world is very high. This could be reduced if the steel was made in the countries with the resources and the finished steel was transported to us. This would lessen the damage, but not entirely.

- They use scrap as new metal will cost a lot to produce and will just be melted away. It is cheaper and easier to just recycle scrap.

- __Advantages__ Cheaper (new metal doesn’t have to produced) __ Disadvantages __ Not as strong as it has been used before.

This link helps: []

__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 2: 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 || <span style="font-size: 12pt; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">0.3 || <span style="font-size: 12pt; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">7.4 ||

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

__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 __<span style="font-size: 12pt; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">How many kg of steel are produced? __ <span style="font-size: 12pt; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">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
 * In the converter process we make steel with the composition: Fe with 0.05 %C and 0.1% Mn.**

__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
 * 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: 12pt; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">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? __ <span style="font-size: 12pt; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">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 <span style="font-size: 13pt; font-family: 'Arial','sans-serif';">π <span style="font-size: 12pt; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">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
 * The combustions of Carbon generated carbon monoxide and carbon dioxide which leave the process as waste gasses.**

<span style="font-size: 8.5pt; font-family: 'MS Shell Dlg','sans-serif';"> <span style="font-size: 12pt; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">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 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 above a critical size is very important.