ACloserLookatIronSmeltingorExtractiveMetallurgy.pptVIP

A Closer Look at Iron Smelting or Extractive Metallurgy The Smelting Process Early smelting operations in Britain involved a two step process: smelting in a charcoal-burning furnace and then refining in a forge (to reduce non-iron content). These required considerable capital, raw materials (iron ore, wood to make charcoal – later coal to make coke, limestone) and a transportation system to distribute the products. Historical Timeline Date Technology 12th c. BCE Tools and weapons made from Fe in meteorites by smelting in bloomeries 1200 BCE Fe + charcoal ? wrought iron 1st c. BCE Oldest existing blast furnace in China 1500 Steel production appeared in Europe 1709 Fe + coke ? cast iron (A. Darby) 2008 Top steel producers: China, US, Japan Bloomery A bloomery was the earliest form of a smelter. Bloomery consists of a heat resistant chimney + pipes at the bottom for air + way to remove product called bloom (reduced iron). Air is added via natural draft or bellows which required power (e.g. Water power) Bloomery - 2 Process: Heat bloomery by burning charcoal or coke; when hot, add iron ore + more fuel + limestone. During the process, iron in the ore is reduced as pure iron pieces fall to bottom of chimney and weld together in a spongy mass to form the bloom. Bloomery - 3 The rest of the ore (impurities) form the slag. It also ends up at the bottom of the chimney including becoming embedded in the bloom. To remove the slag and thus further purify the iron product, the bloom is reheated and then hammered. The product of this process is called wrought iron. Charcoal and Coke Charcoal: Residue left when wood (carbohydrate) is heated in absence of oxygen (anerobic) to drive off water and other volatile components. The porous residue is about 85% carbon and burns hotter and cleaner than wood. Coke: Residue left when coal is heated in absence of oxygen (anerobic) to drive off water and other gases (H2, CH4, CO). Charcoal to Coke Clow and Clow p 331, diagram on p