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 *  __Chapter 1__ **

 ** __What are the main three raw materials used to make iron?__ The three raw materials used to make iron are Iron ore, Coke and Limestone.

__Where do the raw materials come from and how are they transported to the plant?__

Iron ore comes from under the ground in places such as India. Coke is ground down coal. Limestone is a rock found all over the world. These are all transported on ships and trains.

__How and why are the raw materials processed before they are used in the blast furnace?__

Coke is the first material “produced” as it is not a natural material, it is ground down coal. Iron ore is placed in a blast furnace and mainly forms iron but a little iron ore is not converted to iron. The iron ore is mixed with small pieces of coke and heated to form an iron rich clinker called ‘sinter’. Sintering is very important as it reduces waste and provides an efficient raw material for ironmaking in the Blast Furnace. The coke is produced at the works from carefully selected grades of coal. Different grades of coal are blended, for consistency, before they transfer it to ‘batteries’ of coke ovens. It’s heated in sealed ovens to erase the unwanted materials for about 15 hours, then it’s graded and cooled before they put it in the Blast Furnace. Coke ore and sinter are ‘charged’ into the top of the Blast Furnace, together with limestone.

__What role does each of these three raw materials play in the iron-making process?__

The coke reacts with the iron ore and removes the oxygen. A lot of heat is generated which melts the iron ore. The limestone reacts with the iron ore too and removes any impurities. These processes form a waste material called slag which floats on the top. It is easy to remove from the iron.

__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)?__

Mining in the countries which supply iron ore could damage the environment. The machines would destroy the landscape and release CO2. Also with the transportation alot of fuel is consumed and will pollute the atmosphere.

__How can the bad side effects be reduced__ __?__ **  **The bad side effects can be reduced by producing less steel. This is already being done through recycling. The iron ore should also be mined closer to the factory.**

**__ Why is scrap used? __**    ** __Scrap is used to reduce the costs of producing steel and to reduce waste. More than 45% of the steel is made from waste and worldwide the recovery rate is 80%. Also recycling saves on raw materials and emissions of greenhouse gases.__  **  **__ What are the advantages and disadvantages of using scrap in the steel making process? (think for example of temperature control, composition control and production volume.) __   **   Using scrap reduces waste and costs. Because the possibilities for making new products from steel are endless, the world’s steel is kept in continuous circulation. __  Produced ---> Used ---> Recycled |   ** ^ |
 * __  Advantages: