lect 4 smelting123123
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8/20/2019 Lect 4 Smelting123123
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A Closer Look at Iron Smelting
or Extractive Metallurgy
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The Smelting Process
• Early smelting operations in Britain
involve a t!o step process" smelting in a
charcoal#$urning %urnace an then re%ining
in a %orge &to reuce non#iron content'(
• These re)uire consiera$le capital* ra!
materials &iron ore* !oo to make charcoal
+ later coal to make coke* limestone' an atransportation system to istri$ute the
proucts(
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,istorical Timeline
-ate Technology./th c(BCE
Tools an !eapons mae %rom 0e inmeteorites $y smelting in $loomeries
./11 BCE 0e 2 charcoal !rought iron
.st c( BCE 3lest existing $last %urnace in China
.411 Steel prouction appeare in Europe
.516 0e 2 coke cast iron &A( -ar$y'
/117 Top steel proucers" China* 8S* 9apan
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Bloomery
• A $loomery !as the earliest %orm o% a
smelter(
•Bloomery consists o% a heat resistantchimney 2 pipes at the $ottom %or air 2
!ay to remove prouct calle $loom
&reuce iron'(
• Air is ae via natural ra%t or $ello!s
!hich re)uire po!er &e(g( :ater po!er'
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Bloomery # /
• Process" ,eat $loomery $y $urning
charcoal or coke; !hen hot* a iron ore 2
more %uel 2 limestone(
• -uring the process* iron in the ore is
reuce as pure iron pieces %all to $ottom
o% chimney an !el together in a spongy
mass to %orm the $loom(
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Bloomery # <
• The rest o% the ore &impurities' %orm the
slag( It also ens up at the $ottom o% the
chimney incluing $ecoming em$ee in
the $loom(
• To remove the slag an thus %urther puri%y
the iron prouct* the $loom is reheate an
then hammere(• The prouct o% this process is calle
!rought iron(
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Charcoal an Coke
• Charcoal" =esiue le%t !hen !oo
&car$ohyrate' is heate in a$sence o%
oxygen &anero$ic' to rive o%% !ater an
other volatile components( The porousresiue is a$out 74> car$on an $urns
hotter an cleaner than !oo(
• Coke" =esiue le%t !hen coal is heate ina$sence o% oxygen &anero$ic' to rive o%%
!ater an other gases &,/* C,?* C3'(
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Charcoal to Coke
• Clo! an Clo! p
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Blast 0urnace
• Again the re)uire components are iron ore*
%uel &originally charcoal'* oxygen or air an a
!ay to recover the prouct(
• Process" A iron ore an %uel %rom top an
air &the $last' %rom the $ottom resulting in
iron reuction occurring continuously
throughout the %urnace(• =euce iron an slag %all to the $ottom an
are recovere(
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Blast 0urnace # /
• The process o% using coke instea o% charcoal
as the %uel !as %irst evelope an sustaine
$y A$raham -ar$y I in Coal$rookeale in
.516( This !as a maor contri$utor to theInustrial =evolution(
• This %urnace originally mae cast iron pots*
kettles* an later steam engine cyliners(• Later pig iron !as prouce(
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Coke Iron
• A secon $last %urnace !as $uilt in .5.4
!here !ork culminate in .54? &A( -ar$y
II' success%ully proucing iron $ars %rom
pig iron( This le to a huge expansion o%
the iron inustry(
• .5@7 + %irst iron rails
• .557 + A( -ar$y III starte $uiling the %irst
Iron$rige an complete it in .571(
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The Pace o% Technology
• The transition to coke#$ase cast ironprouction %rom charcoal#$ase mallea$leiron prouction took over 41 years even as
%orests !ere eplete* ne! cast#irontechnologies !ere evelope an limitationsovercome" + Lack o% high )uality coal &i(e( lo! in S'
+ Lack o% high )uality coke
+ -eveloping more an ne! sources o% po!er
+ =esistance to change to ne! technology
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• The %irst -ar$y %urnace !as excavate
an is on isplay at Iron$rige(
• The %ollo!ing slie sho!s a moern $alst
%urnace(
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http"!!!(pigiron(org(ukinex
(phpnavD%urnaceprocess
http://www.pigiron.org.uk/index.php?nav=furnaceprocesshttp://www.pigiron.org.uk/index.php?nav=furnaceprocesshttp://www.pigiron.org.uk/index.php?nav=furnaceprocesshttp://www.pigiron.org.uk/index.php?nav=furnaceprocess
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Iron an its Alloys
0e 3xies 0e/3 C 2 Si* Mn* P* S impurities(ery $rittle &!hy calle FpigG iron'
Cast 0e />#?> C 2 .>#@> Si 2 Mn impurities(
Prouce $y heating pig iron toreuce P an S(
C Steel /> C !ith Mn* S* P an Si
:rought0e
H 1(/4> C( ery mallea$le
Alloy Steel Lo! C* $ut !ith ae Cr* M$* i* :
,SLA Microalloye* high strength* lo! alloy
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Properties an 8ses o% Iron D
%&composition'
• At least < types o% pig iron !ere prouce
in the early stages o% smelting( They i%%er
in > 0e* C* etc
+ :hite crue iron" most $rittle* not mallea$le*
very har* $right !hite crystals !hen
%racture(
+ Jrey crue iron" ark granular %ractures* notas har or $rittle* more easily shape
+ Black cast#iron" rough %ractures
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E%%ect o% Iron Impurities on
Properties
C As >C increases* harness increases* $utmallea$ility ecreases(
S Causes hot iron to $e $rittle causing cracks
limite integrity* !el %ailure(Si Leas to gray iron !hich is less $rittle*
pre%erre %or casting(
P Increases harness an strength i% 1(14> H>P H 1(/>( But K 1(/>* iron $ecomes$rittle an unsta$le at lo! T(
Al Mainly impacts slag viscosity &%luiity'(
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