Iron Ore Refining

Iron is a metal which cannot be found naturally in a pure form on earth. It always occurs as a mineral having different content of iron atoms. These minerals are magnetite, siderite, limonite and hematite. The highest concentration of iron atoms in an ore is known to be 70% and there are ores with much less. The iron atoms are mixed with oxygen atoms and silicates in an iron ore and hence iron ore refining is required to separate these bonds, so that pure iron can be produced.

Iron ore refining process uses heat and another substance, so that the oxygen molecules can bond to them and separate from the iron. Carbon readily bonds with oxygen and so coal or coke is used in the iron ore refining process. When the iron ore is heated up to over 900 degrees celsius in the furnace along with coke, the iron will melt and carbon will combine with the oxygen atoms and form different gases like carbon monoxide and carbon dioxide. The furnace for iron ore is built in a particular way so that these gases will escape from the top through a chimney. The iron settles down in the furnace along with the silicates. The silicates are not removed in this process as carbon does not bind with them. The resultant metal is called wrought iron and since ancient times this was used by the blacksmiths to make the several tools and implements. Wrought iron is strong and at the same time malleable, but still contains silicates, and hence is not totally pure form of iron.

Iron ore refining process was modified a little so as to remove these silicates as well and get a more pure form of iron called pig iron. In this process a blast furnace is used which has a silo structure, and limestone is added along with the coke. Limestone contains calcium and it has the capacity to bond with silicates present in the iron ore. After the bonding, the result is a material referred to as slag which forms a layer over the pure molten iron in the furnace. The iron is drained off from an opening at the bottom of the blast furnace.

Pig iron is purer and does not contain any oxygen or silicates and is used to make steel. Pig iron mixed with varying percentage of carbon can create steel of different strengths. Pig iron is also mixed with other elements to produce various alloys having the required properties.

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