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__**Chapter 1 – Raw Materials** __

The main three raw materials to make iron are coke, limestone and iron ore. These materials can come from places such as China, India and Australia; they tend to be sent by freight ship across the ocean. The materials are dropped off at port and from there they are taken by truck to various factories. The largest producer of coke is here in Britain. The iron is processed in a blast furnace along with limestone; this limestone removes impurities from the iron and makes the overall Steel stronger. Limestone reduces the melting point of the impurities, the coke makes the furnace burn brighter and this melts the impurities of the iron and leaves pure iron behind. The ecological effect of transporting the raw materials and then producing iron is, overall, bad. Raw materials are heavy and dirty and take up a lot of space; this limits the amount that can be transported at one time. This then wastes fuel and is damaging to the atmosphere. The process of burning coke to get pure iron produces slag and greenhouse gases. It would be slightly better for the environment to produce steel in the countries that have the raw materials. Scrap is used to save the company money and resources, this is effectively recycling steel. Cheaper, new metal doesn’t have to be produced. Is effectively recycling scrap metal. By using scrap metal it makes the product steel weaker __**Chapter 2 - Conversion** __
 * __Advantage;__**
 * __Disadvantages;__**

 During the conversion 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).   Fe-efficiency of converter process: 98% (2% iron is oxidized) 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
 * || Composition of hot metal (%):  || heat generation of oxidation (MJ/kg)  ||
 * Fe  || 94.9 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">4.3 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">C <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">4.55 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">11.7 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">Si <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">0.25 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">33.9 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> ||
 * <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">Mn <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">0.3 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> || <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">7.4 <span style="font-size: 12pt; color: #0070c0; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> ||

We have 100 kg of hot metal with the compositions above.

__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">**MASS** __ <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-ansi-language: EN-US; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB; mso-bidi-language: AR-SA;">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. **__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">AMOUNT OXIDIZED __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> Fe – 93.002kg C – 4.459 Si – 0.245 Mn – 0.294 <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> **__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">STEEL PRODUCED __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">97.461kg

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 Total = 70.7664
 * __<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">ENERGY GENERATED __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">

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; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">How much energy is used in natural gas a year per household? __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> 32 X 2000= 64000 MJ

**__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">The energy produced from how many kg of hot metal is equivalent to the energy used in natural gas of one household? __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> 64000/70.7664= 904.4 kg <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> **__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; 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; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';"> <span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">2083.5 degrees Celsius

1395700 / 1000 = 1395.7Kj
 * __<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">If we want to melt 1 kg of scrap and heat it to 1650°C how much energy is required? __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">

**__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">How many kg of scrap can be melted with the 100 kg of hot metal making steel of __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> 1650°C? 19.9kg

113.1kg
 * __<span style="font-size: 12pt; color: #0070c0; 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; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">

263 .7 tons of hot metal 56.3 tons of scrap
 * __<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">If we want to make 320 tons of this steel how many tons of hot metal and scrap are required? __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">

320 divided by 7 = 45.7m cubed
 * __<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">How many cubic meters of steel are that? __**<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">

**__<span style="font-size: 12pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;">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: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman'; mso-fareast-language: EN-GB;"> The surface of the bottom of the ladle is <span style="font-size: 13pt; color: #0070c0; line-height: 115%; font-family: 'Arial','sans-serif'; mso-fareast-font-family: 'Times New Roman';">π <span style="font-size: 12pt; color: #0070c0; line-height: 115%; 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 from 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

Before the steel can be used we must first take all of the oxygen out of the steel. To do this we must add aluminium, this reacts with the oxygen in the steel to form aluminium oxide. This process is called, "killing the steel". The aluminium oxide is not extracted from the steel because it does not harm the property of the steel. The lighter particles will float out of the steel, because the particles are lighter than the steel, this is a -Edit here-