TYPES OF IRON

PIG IRON
Basic raw iron is called pig iron because it’s produced in the form of chunky molded
blocks known as pigs. Pig iron is made by heating an iron ore (rich in iron oxide) in a blast
furnace. The blast furnace is an enormous industrial fireplace, shaped like a cylinder, into which
huge drafts of hot air are introduced in regular “blasts”. Blast furnaces are often spectacularly
huge, some are 30 – 60m high, hold dozens of trucks worth of raw materials, and often operate
continuously for years at a time without being switched off or cooled down.
Pig iron is made by melting together an Iron ore sinter/pellets, Limestone & Coke [98%
Carbon] in a blast furnace with an extreme air pressure introduced via the bottom of the furnace.
The process that occurs in the blast furnace basically involves the reduction of the IRON [III]
OXIDE (Fe2O3) to produce IRON (Fe) at about 1550°C. The coke “steals” the oxygen from the
iron oxide (in a chemical process called reduction), leaving behind a relatively pure liquid iron,
while the limestone helps to remove the other parts of the rocky ore (including clay, sand, and
small stones) which form a waste slurry known as SLAG. The main chemical reaction producing
Molten Iron also known as PIG IRON is:
Fe2O3(s) + 3CO(g) → 2Fe(s) + 3CO2(g)
The iron made in a blast furnace is an alloy containing about 90 – 95% iron, 3 – 4% carbon, and
traces of other elements such as silicon, manganese, and phosphorus, depending on the ore used.
Pig iron is much harder than 100 percent pure iron, but still too weak for most everyday
purposes.
CAST IRON
Cast iron is simply liquid iron that has been cast: poured into a mold and allowed to cool
and harden to form a finished structural shape, such as a pipe, a gear, or a big girder for an iron
bridge. Pig iron is actually a very basic form of cast iron, but it’s molded only very crudely
because it’s typically melted down to make steel. The high carbon content of cast iron (about the
same as pig iron roughly 2–4 percent) makes it extremely hard and brittle: large crystals of
carbon embedded in cast iron stop the crystals of iron from moving about. Cast iron has two big
drawbacks: first, because it’s hard and brittle, it’s virtually impossible to shape, even when
heated; second, it rusts relatively easily. It’s worth noting that there are actually several different
types of cast iron, including white and gray cast irons named for the coloring of the finished
product caused by the way the carbon inside it behaves. Cast iron assumes its finished shape the
moment the liquid iron alloy cools down in the mold.
Cast iron is manufactured by remelting pig iron with coke and limestone. This remelting
is done in a furnace known as cupola furnace, which is more or less same as blast furnace. The
cupola is a shaft furnace used for smelting iron for casting production. It is most widely used for
producing molten gray cast iron. Different grades of cast iron are produced according to
specifications. Its shape is cylindrical with diameter about 1m and height of about 5m. The raw
materials are led from the top and the furnace is fired. The impurities of pig iron are removed to
some extent by oxidation. The molten cast iron is led into moulds of required shapes to form
what are known as cast iron castings and slag is removed from the top of cast iron at regular
intervals.
COMPOSITION OF CAST IRON:
1. Cast iron contains about 2 to 4 percent of carbon.
2. Manganese makes cast iron-brittle and hard, so it may be kept below 0.75 percent.
3. Phosphorous makes brittle and percentage may be 1 to 1.5 percent.
4. Silicon decreases shrinkage and ensures softer and better castings and it may be less than
2.5 percent.
5. Sulphur makes cast iron brittle and hard and should be kept below 0.10 percent.
USES CAST IRON:
1. For making cisterns, water pipes, gas pipes and sewers, manhole covers and sanitary
fittings.
2. For making ornamental castings like brackets, gates, lampposts etc.
3. For making parts of machinery which are not subjected to shock loads.
4. For manufacture of compression members.
5. For preparing rail chairs, carriage wheels etc.

WROUGHT IRON
Wrought iron is a very different material made by mixing liquid iron with some slag
(leftover waste). The result is an iron alloy with a much lower carbon content. Wrought iron is
softer than cast iron and much less tough, so you can heat it up to shape it relatively easily, and
it’s also much less prone to rusting. However, relatively little wrought iron is now produced
commercially, since most of the objects originally produced from it are now made from steel,
which is both cheaper and generally of more consistent quality. Wrought iron is what people
used to use before they really mastered making steel in large quantities in the mid-19 th century.
Due to its ability to withstand extreme weather conditions and its high resistance to
corrosion, it is suitable for outdoor & indoor applications such as: Bolts & Nuts, Rivets,
Ornamental iron work, etc.
 STEEL MAKING PROCESS
Steelmaking 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.
The basic raw material for steel manufacture is either the hot metal from the blast
furnace, steel scrap or a mixture of both. The proportions of material used vary according to the
process and the type of steel required. Steel can be described in general terms as iron with most
of the carbon removed, to make it tougher and more ductile.
BASIC OXYGEN FURNACE
Hot metal from the blast furnace and steel scrap are the principal materials used in Basic
Oxygen Furnace (BOF). BOF will take a charge of up to 350 tonnes and convert it into steel in
around 15 minutes. A water-cooled oxygen lance is lowered into the converter and high-purity
oxygen is blown on to the metal at very high pressure. The oxygen combines with carbon and
other unwanted elements, eliminating them from the molten charge. These oxidation reactions
produce heat, and the temperature of the metal is controlled by the quantity of added scrap. The
carbon leaves the converter as CO which can, after cleaning, be collected for re-use as a fuel.
During the ‘blow’, lime is added as a flux to help carry off the other oxidized impurities as a
floating layer of slag. The quantities of scrap, hot metal and lime and other fluxes are calculated
to ensure the correct steel temperature and composition. The refining process is assisted by the
injection of gases, including argon, nitrogen and carbon dioxide, through the base of the furnace.
After the steel has been refined and samples taken to check temperature and composition, the
converter is tilted and the steel is tapped into a ladle. Typically, the carbon content of the steel at
the end of refining is about 0.04%. During tapping, alloy additions can be made to adjust the
final composition of the steel.
When all the steel has been tapped, the converter is turned upside down and the residual slag is
tipped into a waiting slag ladle for removal to a slag cooling pond, from where it is further
processed to reclaim any material which can be returned to the process.
 BASIC OXYGEN FURNACE DIAGRAM

ELECTRIC ARC FURNACE

The electric arc furnace consists of a circular bath with a movable roof, through which
three graphite electrodes can be raised or lowered. At the start of the process, the electrodes are
withdrawn and the roof swung clear. The steel scrap is then charged into the furnace from a large
steel basket lowered from an overhead travelling crane. When charging is complete, the roof is
swung back into position and the electrodes lowered into the furnace. A powerful electric current
is passed through the charge, an arc is created, and the heat generated melts the scrap. Lime and
fluorspar are added as fluxes and oxygen is blown into the melt. As a result, impurities in the
metal combine to form a liquid slag. Samples of the steel are taken and analysed to their check
composition and, when the correct composition and temperature have been achieved, the furnace
is tapped rapidly into a ladle. Electric arc furnace steelmaking typically uses furnaces of capacity
around 100 tonnes that produce steel every 40 to 50 minutes. This process allows larger alloy
additions than the basic oxygen
method.

ELECTRIC ARC FURNACE

OPEN-HEARTH PROCESS
The open-hearth process is a batch process called a “heat”. The furnace is first inspected
for possible damage. Once it is ready or repaired, it is charged with light scrap, such as sheet
metal, shredded vehicles or waste metal. The furnace is heated using burning gas. Once the
charge has melted, heavy scrap, such as construction or steel milling scrap is added, together
with pig iron from blast furnaces. Once all the steel has melted, slag-forming agents such as
limestone are added. Atmospheric oxygen in contact with molten pig iron directly oxidizes the
carbon excess in it contains to form carbon monoxide (CO). Additionally, Fe(II) present in
iron(II) oxide (FeO) and other impurities also contribute to decarburize the pig iron by oxidizing
carbon into CO and simultaneously reducing Fe(II) into metallic Fe. The formed carbon
monoxide (CO) is flushed away in the fumes, while steel is formed. To increase the oxidizing
power of the “heat”, more iron oxide ore can be added.
 The process is far slower and thus easier to control and sample for quality assessment.
Preparing a heat usually takes 8-81/2 hours, and longer to finish the conversion into steel. As the
process is slow, it is not necessary to burn all the carbon away but the process can be terminated
at any given point when the desired carbon content has been achieved. The furnace is tapped in
the same way a blast furnace is tapped; a hole is drilled in the side of the hearth and the raw steel
flows out. Once all the steel has been tapped, the slag is skimmed away. The raw steel may be
cast into ingots, a process called teeming, or it may be used in continuous casting in the rolling
mill.

The final step to steel production Is the secondary forming technique, which gives the
steel products their final shape and properties. This is done by:
1. Shaping (cold rolling methods)
2. Machining (eg: drilling)
3. Joining (by means of welding)
4. Coating – galvanising with zinc, or cold coating and electro coating
5. Heat treatment (usually tempering)
6. Surface treatment (carburising)
TYPES OF STEEL
The four main types of steel are:
1. Carbon Steel: Carbon steel is unique for the notable absence of other elements in its
makeup. Though it only contains 2% carbon or less by weight, its elemental nature makes
carbon steel a strong, durable material that is ideal for numerous uses. Carbon steel’s
relative adaptability and low cost make it an ideal choice for a variety of construction
projects, both large and small-scale. This steel can be categorized into three groups:
 a. Low carbon steel (also known as mild steel), which typically contains 0.04% to
0.30% carbon content.
b. Medium carbon steel, which typically has a carbon range of 0.31% to 0.60%
c. High carbon steel, which typically contains 0.61% and 1.50%.
2. Alloy Steel: Alloy steels contain one or more other elements, such as chromium, copper,
manganese, nickel, silicon, or vanadium. Most alloy steels are better for welding,
resistant to rust, stronger or more tactile. They are suitable in more specialized industries,
such as shipbuilding, automotive, and appliances. Alloy steels are generally more
responsive to heat and mechanical treatments than carbon steels. Some of the most
common alloys include:
a. Aluminum: Lightweight, heat-resistant steel that’s ductile and easy to work with
and is often used in hot exhaust systems and power generators.
b. Copper: Corrosion-resistant steel that conducts heat very efficiently, making it a
great choice for electrical wiring and industrial heat exchangers.
c. Silicon: Soft-natured steel that’s malleable and highly magnetic. Silicon creates
strong permanent magnets power plants need for their electrical transformers.
d. Molybdenum: Weld-able, corrosion-resistant steel that performs well under high
pressure, making it suitable for underwater construction or oil and gas pipelines.
e. Manganese: Impact-resistant steel that’s extremely tough. It is used in bulletproof
cabinets, anti-drill plates and high-strength safes.
f. Vanadium: High-impact steel that’s shock-absorbent and vibration-resistant. It is
used for automotive parts like shocks and springs.
3. Stainless Steel: Stainless steel is a steel alloy that has good corrosion resistance
properties due to the presence of chromium that varies between 10-20%. Other alloys
include nickel and molybdenum. Common applications for stainless steel include cutlery,
medical instruments, hardware, appliances, and architectural fittings. Stainless steel is
grouped into four subcategories, namely;
a. Martensitic alloys
b. Austenitic alloys
c. Duplex alloys
d. Ferritic alloys
4. Tool Steel: Tool steels contain alloys like tungsten, molybdenum, cobalt and vanadium
in various quantities, and are extremely hard, durable and resistant to heat. As the name
implies, they are used in tool applications, such as cutting, mould-making, or impact
tools. Tool steel are of different types;
a. Air-hardening tool steel
b. Water-hardening tool steel
c. Hot-working tool steel
d. Shock-resisting tool steel
e. Oil-hardening tool steel
f. High speed tool steel