Metallurgical furnaceA metallurgical furnace, more commonly referred to as a furnace, is an industrial furnace used to heat and melt metal ore to remove gangue, primarily in iron and steel production. The heat energy to fuel a furnace may be supplied directly by fuel combustion, by electricity such as the electric arc furnace, or through induction heating in induction furnaces. There are several different types of furnaces used in metallurgy to work with specific metal and ores. Smelting furnaces are used in smelting to extract metal from ore.
Extractive metallurgyExtractive metallurgy is a branch of metallurgical engineering wherein process and methods of extraction of metals from their natural mineral deposits are studied. The field is a materials science, covering all aspects of the types of ore, washing, concentration, separation, chemical processes and extraction of pure metal and their alloying to suit various applications, sometimes for direct use as a finished product, but more often in a form that requires further working to achieve the given properties to suit the applications.
Electric arc furnaceAn electric arc furnace (EAF) is a furnace that heats material by means of an electric arc. Industrial arc furnaces range in size from small units of approximately one-tonne capacity (used in foundries for producing cast iron products) up to about 400-tonne units used for secondary steelmaking. Arc furnaces used in research laboratories and by dentists may have a capacity of only a few dozen grams. Industrial electric arc furnace temperatures can reach , while laboratory units can exceed .
SteelSteel is an alloy of iron and carbon with improved strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels, which are resistant to corrosion and oxidation, typically need an additional 11% chromium. Because of its high tensile strength and low cost, steel is used in buildings, infrastructure, tools, ships, trains, cars, bicycles, machines, electrical appliances, furniture, and weapons. Iron is the base metal of steel.
Blast furnaceA blast furnace is a type of metallurgical furnace used for smelting to produce industrial metals, generally pig iron, but also others such as lead or copper. Blast refers to the combustion air being supplied above atmospheric pressure. In a blast furnace, fuel (coke), ores, and flux (limestone) are continuously supplied through the top of the furnace, while a hot blast of air (sometimes with oxygen enrichment) is blown into the lower section of the furnace through a series of pipes called tuyeres, so that the chemical reactions take place throughout the furnace as the material falls downward.
Ferrous metallurgyFerrous metallurgy is the metallurgy of iron and its alloys. The earliest surviving prehistoric iron artifacts, from the 4th millennium BC in Egypt, were made from meteoritic iron-nickel. It is not known when or where the smelting of iron from ores began, but by the end of the 2nd millennium BC iron was being produced from iron ores in the region from Greece to India, and sub-Saharan Africa. The use of wrought iron (worked iron) was known by the 1st millennium BC, and its spread defined the Iron Age.
SteelmakingSteelmaking is the process of producing steel from iron ore and/or scrap. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon (the most important impurity) are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel. Steelmaking has existed for millennia, but it was not commercialized on a massive scale until the mid-19th century. An ancient process of steelmaking was the crucible process.
Open hearth furnaceAn open-hearth furnace or open hearth furnace is any of several kinds of industrial furnace in which excess carbon and other impurities are burnt out of pig iron to produce steel. Because steel is difficult to manufacture owing to its high melting point, normal fuels and furnaces were insufficient for mass production of steel, and the open-hearth type of furnace was one of several technologies developed in the nineteenth century to overcome this difficulty.
Mineral processingIn the field of extractive metallurgy, mineral processing is the process of separating commercially valuable minerals from their ores. Depending on the processes used in each instance, it is often also known as ore dressing or ore milling. Before the advent of heavy machinery the raw ore was broken up using hammers wielded by hand, a process called "spalling". Before long, mechanical means were found to achieve this. For instance, stamp mills were used in Samarkand as early as 973. They were also in use in medieval Persia.
Metallurgical coalMetallurgical coal or coking coal is a grade of coal that can be used to produce good-quality coke. Coke is an essential fuel and reactant in the blast furnace process for primary steelmaking. The demand for metallurgical coal is highly coupled to the demand for steel. Primary steelmaking companies often have a division that produces coal for coking, to ensure a stable and low-cost supply. Metallurgical coal comes mainly from Canada, the United States, and Australia, with Australia exporting 58% of seaborne trade, mostly going to China.
Stainless steelStainless steel, also known as inox or corrosion-resistant steel (CRES), is an alloy of iron that is resistant to rusting and corrosion. It contains at least 10.5% chromium and usually nickel, and may also contain other elements, such as carbon, to obtain the desired properties. Stainless steel's resistance to corrosion results from the chromium, which forms a passive film that can protect the material and self-heal in the presence of oxygen. The alloy's properties, such as luster and resistance to corrosion, are useful in many applications.
Bessemer processThe Bessemer process was the first inexpensive industrial process for the mass production of steel from molten pig iron before the development of the open hearth furnace. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron. The oxidation also raises the temperature of the iron mass and keeps it molten. Related decarburizing with air processes had been used outside Europe for hundreds of years, but not on an industrial scale.
MetallurgyMetallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their inter-metallic compounds, and their mixtures, which are known as alloys. Metallurgy encompasses both the science and the technology of metals; that is, the way in which science is applied to the production of metals, and the engineering of metal components used in products for both consumers and manufacturers. Metallurgy is distinct from the craft of metalworking.
Basic oxygen steelmakingBasic oxygen steelmaking (BOS, BOP, BOF, or OSM), also known as Linz-Donawitz steelmaking or the oxygen converter process, is a method of primary steelmaking in which carbon-rich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into low-carbon steel. The process is known as basic because fluxes of burnt lime or dolomite, which are chemical bases, are added to promote the removal of impurities and protect the lining of the converter.
Iron oreIron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, or deep purple to rusty red. The iron is usually found in the form of magnetite (Fe3O4, 72.4% Fe), hematite (Fe2O3, 69.9% Fe), goethite (FeO(OH), 62.9% Fe), limonite (FeO(OH)·n(H2O), 55% Fe) or siderite (FeCO3, 48.2% Fe). Ores containing very high quantities of hematite or magnetite, typically greater than about 60% iron, are known as natural ore or direct shipping ore, and can be fed directly into iron-making blast furnaces.
Cast ironCast iron is a class of iron–carbon alloys with a carbon content more than 2%. Its usefulness derives from its relatively low melting temperature. The alloy constituents affect its color when fractured; white cast iron has carbide impurities which allow cracks to pass straight through, grey cast iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material breaks, and ductile cast iron has spherical graphite "nodules" which stop the crack from further progressing.
Reverberatory furnaceA reverberatory furnace is a metallurgical or process furnace that isolates the material being processed from contact with the fuel, but not from contact with combustion gases. The term reverberation is used here in a generic sense of rebounding or reflecting, not in the acoustic sense of echoing. Chemistry determines the optimum relationship between the fuel and the material, among other variables.
Ductile ironDuctile iron, also known as ductile cast iron, nodular cast iron, spheroidal graphite iron, spheroidal graphite cast iron and SG iron, is a type of graphite-rich cast iron discovered in 1943 by Keith Millis. While most varieties of cast iron are weak in tension and brittle, ductile iron has much more impact and fatigue resistance, due to its nodular graphite inclusions. On October 25, 1949, Keith Dwight Millis, Albert Paul Gagnebin and Norman Boden Pilling received US patent 2,485,760 on a cast ferrous alloy for ductile iron production via magnesium treatment.
Heavy metalsHeavy metals are generally defined as metals with relatively high densities, atomic weights, or atomic numbers. The criteria used, and whether metalloids are included, vary depending on the author and context. In metallurgy, for example, a heavy metal may be defined on the basis of density, whereas in physics the distinguishing criterion might be atomic number, while a chemist would likely be more concerned with chemical behaviour. More specific definitions have been published, none of which have been widely accepted.
Iron AgeThe Iron Age is the final epoch of the three-age division of the prehistory and protohistory of humanity. It was preceded by the Stone Age (Paleolithic, Mesolithic, Neolithic) and the Bronze Age. The concept has been mostly applied to Iron Age Europe and the Ancient Near East, but also, by analogy, to other parts of the Old World. It is also considered the third phase, of three, in the Metal Ages. The duration of the Iron Age varies depending on the region under consideration. It is defined by archaeological convention.
