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Mechanical Engineering Mechanical Engineering TechnologyTechnologyThe Production of Ferrous MetalsThe Production of Ferrous Metals At the end of the lesson students

should be able to:1. Define the three main ingredients

used in the production of iron and steel.2. Draw and explain the diagram of

production of iron and steel (ferrous metals).

3. Define other processes involved in the production process.

4. List the end products of iron and steel.

The Production of Iron & Steel.The Production of Iron & Steel.The importance of metals to man in today's world cannot be overemphasized because we use them in our everyday life.Metals are divided into three main groups; Ferrous, Non-ferrous Alloys.

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Non-Ferrous MetalsNon-Ferrous MetalsThese contain little or no iron and

they do not rust when exposed to air.

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These contain mainly iron and they These contain mainly iron and they rust easily when exposed to air.rust easily when exposed to air.

REVIEW OF PRODUCTION OF IRON REVIEW OF PRODUCTION OF IRON AND STEELAND STEEL

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Production of iron & steel begins in a blast furnace.

REVIEW OF PRODUCTION OF IRON REVIEW OF PRODUCTION OF IRON AND STEELAND STEEL

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The “Charge” is fed into the furnace.

Iron oreIron ore

CokeCoke

LimestoneLimestone

REVIEW OF PRODUCTION OF IRON REVIEW OF PRODUCTION OF IRON AND STEELAND STEEL

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The coke is burned as a The coke is burned as a fuel to heat the furnacefuel to heat the furnace . .

The iron ore melts and forms The iron ore melts and forms molten iron called pig ironmolten iron called pig iron..

The limestone melts & acts as The limestone melts & acts as a flux that collects the a flux that collects the impurities given offimpurities given offduring the smelting process.during the smelting process.

REVIEW OF PRODUCTION OF IRON AND STEELREVIEW OF PRODUCTION OF IRON AND STEEL

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MoltenMoltenmetalmetal

BlastBlastfurnacefurnace

CokeCokeIron oreIron ore

LimestoneLimestoneContinuousContinuous

CastingCasting

ElectricElectricArcArc

FurnaceFurnace

CupolaCupolaFurnaceFurnace

AlloyAlloySteelsSteels

Cast ironCast iron

IINNGGOOTTSS

SOAKINGSOAKINGPITSPITS

Other processingOther processing

The Production of Ferrous The Production of Ferrous MetalsMetals

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Blast FurnaceBlast Furnace

Pig IronPig Iron

Cupola FurnaceCupola Furnace Puddling FurnacePuddling Furnace Bessemer ConverterBessemer Converter

Cast IronCast Iron Wrought IronWrought Iron Mild SteelMild Steel

Iron oreIron oreLimestoneLimestone

cokecoke

CASTINGCASTING Process of pouring hot liquid metal into a mould.

Upon solidification the metal takes the shape of the mould.

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CONTINUOUS CASTINGCONTINUOUS CASTING

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PRODUCTS FROM CONTINUOUS CASTINGPRODUCTS FROM CONTINUOUS CASTING

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PRODUCTS FROM CONTINUOUS PRODUCTS FROM CONTINUOUS CASTINGCASTING

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LET’S REVIEWLET’S REVIEW Production of iron and steel begins in a

______________ ____________

The ingredients placed in the furnace are

__________ __________ ________ Cast iron is the product of the

_______furnace13

blast furnaceblast furnace

coke iron ore limestonecoke iron ore limestone

cupolacupola

LET’S REVIEWLET’S REVIEW __________ __________ called pig iron

is drawn from the blast furnace and taken for further processing.

The pouring of liquid metals into moulds is referred to as ________________.

Continuous casting, casts directly into shapes such as __________ _________ ________.

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Molten metalMolten metal

castingcasting

blooms slabs billetsblooms slabs billets

REFERENCESREFERENCES

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http://www.britannica.com/eb/article-81416 Reviewed July 12, 2006

http://en.wikipedia.org/wiki/Continuous_Casting Reviewed July 12, 2006

http://frisch-gmbh.de/images/stranggiessen.jpg Reviewed July 14, 2006

http://www.me.gatech.edu/jonathan.colton/me4210/flowline1.gif Reviewed July 14, 2006

http://www.amk.al.lg.ua/images/diagram.jpg Reviewed July 15, 2006

http://www.schoolscience.co.uk/content/4/chemistry/steel/images/slabbb.gif Reviewed July 15, 2006

Kozak, Bruce., Dzierzawski , Joseph. , SMS Demag http://www.steel.org Reviewed July 19, 2006