C3T+group4

The three main groups of raw materials used to make iron are - Iron ore - coal - limestone.
 * p. 5 What are the main three raw materials used to make iron?**

The raw materials come from deep down underground and are directly transported to the plant by a freight train.
 * Where do the raw materials come from and how are they transported to the plant?**

The materials are processed so that the right properties can be found.
 * How and why are the raw materials processed before they are used in the blast furnace?**

2000 m3 in natural gas is used per household.
 * p. 6**
 * How Much energy is used in natural gas a year per household?**

64000Mj/m3
 * The energy produced from how many kg of hot metal is equivelent to the energy used in natural gas of one household?**


 * p. 13**

//Cutting the blank//

 * 1 The modern method for making aluminum beverage cans is called two-piece drawing and wall ironing. The process begins with an aluminum ingot which was cast to be about 30 inches (76 cm) thick, then rolled into a thin sheet. The first step in the actual manufacture of the can is to cut the sheet into a circle, called a blank, that will form the bottom and sides of the can. Each blank is 5.5 inches (14 cm) in diameter. Some material is necessarily lost between each circle, but manufacturers have found that minimum aluminum is lost when the sheets are wide enough to hold two staggered rows of seven blanks each. About 12-14% of the sheet is wasted, but can be reused as scrap. After the circular blank is cut, it is "drawn" or pulled up to form a cup 3.5 inches (8.9 cm) in diameter.

//Redrawing the cup//

 * 2 The small cup resulting from the initial draw is then transferred to a second machine. A sleeve holds the cup precisely in place, and a punch lowered swiftly into the cup redraws it to a diameter of about 2.6 inches (6.6 cm). The height of the cup increases simultaneously from the initial 1.3 to 2.25 inches (3.3 to 5.7 cm). The punch then pushes the cup against three rings called ironing rings, which stretch and thin the cup walls. This entire operation—the drawing and ironing—is done in one continuous punch stroke, which takes only one fifth of a second to complete. The cup is now about 5 inches (13 cm) high. Then another punch presses up against the base of the cup, causing the bottom to bulge inward. This shape counteracts the pressure of the carbonated liquid the can will contain. The bottom and lower walls of the can are also a little thicker than the upper walls, for added strength.

//Trimming the ears//

 * 3 The drawing and ironing process leaves the can slightly wavy at the top. These small ripples in the metal are called "ears." "Earing" is an unavoidable effect of the crystalline structure of the aluminum sheet. Aluminum companies have studied this phenomenon extensively, and they have been able to influence the placement and height of the ears by controlling the rolling of the aluminum sheet. Nevertheless, some material is lost at this stage. About a quarter inch is trimmed from the top of the can, leaving the upper walls straight and level.

//Cleaning and decorating//

 * 4 The drawing and ironing process leaves the outer wall of the can with a smooth, shiny surface, so it does not require any further finishing such as polishing. After the ears are trimmed, the can is cleaned and then imprinted with its label. After the can is decorated, it is squeezed in slightly at the top to a make a neck, and the neck is given an out-ward flange at the very top edge, which will be folded over once the lid is added.

//The lid//
To ensure that the cans are made properly, they are automatically checked for cracks and pinholes. One in 50,000 cans is usually found to be defective.
 * 5 The lid is made of a slightly different alloy than the aluminum for the base and sides of the can. The inward bulge of the bottom of the can helps it withstand the pressure exerted by the liquid inside it, but the flat lid must be stiffer and stronger than the base, so it is made of aluminum with more magnesium and less manganese than the rest of the can. This results in stronger metal, and the lid is considerably thicker than the walls. The lid is cut to a diameter of 2.1 inches (5.3 cm), smaller than the 2.6-inch (6.6 cm) diameter of the walls. The center of the lid is stretched upward slightly and drawn by a machine to form a rivet. The pull tab, a separate piece of metal, is inserted under the rivet and secured by it. Then the lid is scored so that when the tab is pulled by the consumer, the metal will detach easily and leave the proper opening.
 * **How many coils of 10 tons can the plant process in a year**?
 * a can making plant produces 100.000 cans an hour.
 * 1 hour= 100.000x 0.025 kilograms a piece : 0.75 (75%) = 3333.33 kg
 * 1 year= 3333.33: 1000 x 24 hours x 365days x 0.9 (90%) = 26280 tons
 * number of 10 coils = 26280 tonnes :10 = 2628 coils
 * **How many cans are produced per year?**
 * 100.000x 24 hours x 365 days x 0.9 (90%) = 788.4 million cans
 * **How many rejected cans per slab and per year are allowed?**
 * 100.000 cans equals 3333.33 kg so 10 tons equals 300.000cans
 * 2 ppm of 300.000 cans = 0.6 cans
 * per year
 * 0.6 x 2628= 1576.8 rejected
 * 1576.8 : 365 = 4.32 per day rejected
 * **How many square meters storage are required to store a week production?**
 * cans per week: 100.000x24x7x 0.9 (90%)=16.8 million cans
 * space per can: 16.800.000 x 0.125 : 4m high x 0.075 x 0.075 = 2953.125 m2
 * What are the main differences between steel and aliminium cans from a recycling point of view? (think for example of waste seperation, chemical composition)
 * cans per week: 100.000x24x7x 0.9 (90%)=16.8 million cans
 * space per can: 16.800.000 x 0.125 : 4m high x 0.075 x 0.075 = 2953.125 m2
 * What are the main differences between steel and aliminium cans from a recycling point of view? (think for example of waste seperation, chemical composition)
 * What are the main differences between steel and aliminium cans from a recycling point of view? (think for example of waste seperation, chemical composition)

Ferrous metals
Iron and steel are the world's most recycled materials, and among the easiest materials to recycle, as they can be separated magnetically from the waste stream. Recycling is via a steelworks: scrap is either remelted in an Electric Arc Furnace (90-100% scrap), or used as part of the charge in a Basic Oxygen Furnace (around 25% scrap). Any grade of steel can be recycled to top quality new metal, with no 'downgrading' from prime to lower quality materials as steel is recycled repeatedly. 42% of crude steel produced is recycled material. 

Non-ferrous metals
[|Aluminium] is shredded and ground into small pieces or crushed into bales. These pieces or bales are melted in an aluminium smelter to produce molten aluminium. By this stage the recycled aluminium is indistinguishable from virgin aluminium and further processing is identical for both. Some materials like aluminum can be recycled indefinitely as there is no change to the materials. Recycling aluminium saves 95% of the energy cost of processing new aluminium because the melting temperature is reduced from 900 °C to 600 °C. It is by far the most efficient material to recycle. Due to the high melting point of aluminium ore, large amounts of energy are required to extract aluminium from ore, making the environmental benefits of recycling aluminium enormous. Recycling aluminium only results in approximately 5% of the CO2 that would be released during the production of raw aluminium. The percentage is even smaller when considering the complete cycle of mining and transporting the aluminium. Also, as [|open-cut mining] is most often used for obtaining aluminium ore, mining destroys large sections of natural land. An aluminium can is 100% recyclable. Every time a can is recycled, enough energy is saved to power a television for about three hours (compared to mining and producing a new can). members of the group:** Robbert Jelle Z Madelon Eline Tom Laura
 * [[image:http://www.messingerbearings.com/images/applications1.gif width="156" height="203" align="right" caption="external image applications1.gif"]]

**metallurgy installation:** an installation where a chemical composition **A tundish:** is used to hold molten metal, and can also be used in filling moulds. The tundish allows a reservoir of metal to feed the casting machine. **A mould: ** is a hollowed-out block that is filled with a liquid like plastic, glass, metal or ceramic raw materials. The liquid hardens or sets inside the mould, adopting its shape. **Inclusion:** is when a material is trapped in a mineral during formation. **Solidify:** is to make something solid, hard and strong. **A slab o steel:** if is a plate of steel. **A coil of steel:** is a big roll of steel. **Waste separation:** is the excluding of waste.
 * Glossary:**
 * raw materials:** something that's acted upon by human labour or industry to create some product that human's desire
 * blast furnace:** it's a type of metallurgical furnace used for smelting to produce metals, generally iron.
 * refractory :** refers to the quality of a material to retain its strength at high temperature.
 * ladle:** a container used to transport and pour out molten metals.
 * converter:** a machine which converts one kind of fuel into another.
 * slag:** the by-producht of smelting ore to purify metals.
 * scrap:** anything that's left over (useful to recycles)
 * combustion:** or burning. Is a complex sequence of exothermic chemical reactions between a fuel and a oxidant accompanied by the production of heat or both heat and light in the form of either a glow or flames
 * Continuous casting:** is the refining of the casting process for the continuous production of metal sections with a constant cross-section. It allows lower cost production of metal sections with better quality, due to the lower cost and the increased control on the manufacturing process because of automation.