GuyWinter

 __Chapter 1; __There are three main raw materials used to make iron; iron ore ( haematite), coke and limestone. These materials are produced all over the world. The main supplier of coke is from Northern America. Haematite or iron ore is most often exported from South America, Australia and Asia. The final material limestone can be found in India. These materials can be transported to Corus factories worldwide. If they needed to transport huge amounts of Iron ore from South America to Holland, the cargo would be sent via huge cargo ships aver the sea. If the materials needed to be transported across large area of land, they will most likely be sent via rail. Before entering the blast furnace, the materials must be processed in order to get the results required.  Because it is found in coal, coke must be processed in order to extract it from the coal. This process is also known as the ‘coking’ process. The process involves baking the coal at extremely high temperatures (as high as 2000 degrees Celsius) in an airless furnace. These extreme temperatures drive away water, coal-gas and coal-tar triggering the fixed carbon and residual ash to fuse together. After this, the coke is then cooled instantly by dousing it with water. Coke is the only one of the 3 main raw materials of iron that needs to be produced. Each of the three raw materials has their own role to play in the iron making process. Coke helps rise the temperatures inside the blast furnace. Limestone helps melt all of the impurities in the blast furnace. The final main raw material – iron ore – is the main pure element.
 * __Corus project __**

Using these raw materials has bad ecological effects on the environment. Because most of the materials come from faraway places such as America and Asia, they must be transported over large distances. This requires large amounts of fuel which can damage the environment and the atmosphere. As well as this, the country or company will have to pay for this fuel and transport. They then have to be transported over land via lorries, trucks or rail. This also damages the environment because they burn fossil fuels. This also costs money for the country and company. The landscapes of the country could also be damaged because all of the materials come from underground. This means that they must be dug up via mining or digging. These side effects can be reduced by putting factories in places closest to the most bulky materials. This will reduce the needs for transport costing the environment, Country and company less.

In the basic oxygen furnace, scrap metal is used. It is used mainly because it is cheep and does not require any additional making of metal. There are advantages of using scrap and there are also some disadvantages. The main advantages are that scrap is cheap and does not require additional metal making. The main disadvantages is that it must be transported which costs money and the metal will not be as strong as it has been used previosly.

 1. If we have 100kg of hot metal, the mass of each element would be; Fe = 94.9kg C = 4.55kg Si = 0.25kg Mn = 0.3kg
 * __Chapter 2 __****__: __**

2. Amount of each element oxidised: - Iron=0.02x94.9=1.898 Carbon=0.02x4.55=0.091 Silicon=0.02x0.25=0.005 Manganese=0.02 Kg of each element when we have 100kg:- 94.9% iron 4.55% Carbon 0.25% Silicon 0.3% Manganese

3. Kg of steel produced is 100Kg- 1.898Kg of Fe – 4.5Kg of carbon – 0.25Kg of Si – 0.2Kg of Mn **= ** 93Kg

4. Amount of energy generated during the process:- Iron 4.3x1.898= 8.1614 Carbon 11.7x4.5=52.65 Silicon 33.9x0.25=8.47 Manganese 7.4x0.2=1.48 So Iron, Carbon, Silicon and Manganese added together 8.1614+52.65+8.475+1.48=70.7664

5. Amount of energy used in natural gas each year per household: - 2000 x 32 = 64000MJ.

6. Kg of hot metal: - 64000 / 70.7664 = 904.4kg.


 * __Chapter 4: __**

1. The amount of 10 ton coils a plant can process in a year =2628 coils. A can making plant makes 100,000 can / hr. 1 can weighs 25 grams. Out of this only 75% is used. So, only 75Kg of cans are made from 100Kg of steel. The amount of can a plant can produce a year is 100,000 cans / hour X 25g = 2500Kg / hour. So as 75% is used 2500 / 0.75= 3333.3Kg used / hr. So 10 ton coil (10,000Kg) is used every 3 hours. (10,000 / 3333Kg)So 3333.3Kg / hr: 365 days X 24 hours= 8760 hours Plant operates 90% of time = 0.9 X 8760= 7884 hours. Number of coils used =operating time / time to use 1 coil Number of coils used = 7884 / 3 = **__2628 coils.__**

2. Cans produced per year:- 100000 x 24 = 2400000 ---> 2400000 x 365 = 876000000 ---> 876000000 x 0.9 = 788400000

3. Rejected cans per; Slab:- Year: - 1576.8