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MME302 Note Vol.2

The document provides an overview of iron extraction, detailing the types of iron ores, their occurrence in Nigeria, and the mining process. It explains the blast furnace method used to convert iron ore into metallic iron through chemical reactions involving coke and limestone. The document also outlines the chemistry behind the extraction process and the role of various materials in producing molten iron.

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6 views7 pages

MME302 Note Vol.2

The document provides an overview of iron extraction, detailing the types of iron ores, their occurrence in Nigeria, and the mining process. It explains the blast furnace method used to convert iron ore into metallic iron through chemical reactions involving coke and limestone. The document also outlines the chemistry behind the extraction process and the role of various materials in producing molten iron.

Uploaded by

lollyvenicel
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Iron ore processing

8
Chapter Two
2.0 Iron Extraction

Iron and iron ores


Iron (Fe), a silvery-white metal, is the most abundant metal on Earth known for its
magnetism and use in manufacturing steel and other alloys. Iron is the 4th most
abundant element in the earth. In nature it exists in the form of ores (rocks that contain
minerals).

In the Periodic table, it has Symbol Fe ; Atomic Number of 26; Melting Point: 1538°C;
Boiling Point: 2861°C; Density: 7.87 g/cm³ Metallic iron extracted from ore is the metal
most widely used by man.
Most iron ores are oxides (contain oxygen). To obtain metallic iron, the oxygen atoms
must be removed from the ore. There are several different processes for this extraction.
Most include heating the iron ore to cause chemical reactions.

Figure 2.1: Iron ore

Types of Iron ores

1. Magnetite (Fe3O4) - best quality iron ore. Magnetite, also called lodestone. It is a
natural magnet, hence the name, giving it a distinguishing characteristic.

2. Siderite is a mineral composed of iron(II) carbonate (FeCO3). Its name comes from the
Ancient Greek word σίδηρος (sídēros), meaning "iron"

3. Hematite (Fe₂O₃) is a common iron oxide mineral, a primary source of iron ore, and
known for its reddish-brown to black color and reddish-brown streak.

4. Limonite is a general term for a mixture of fine-grained iron oxides, generally


dominated by goethite, but also possibly containing hematite

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Occurrence and exploration of Iron ore in Nigeria
Nigeria has substantial iron ore reserves, estimated at over 3 billion metric tonnes, with
notable deposits in Kogi, Enugu, Niger, and Kaduna states, including the Itakpe mine in
Kogi State. Nigeria is rich in iron ore, with proven deposits exceeding 3 billion metric
tonnes spread across several states.

Mining Iron Ore


Before all else, iron ore is mined from the earth. Most of the world’s iron ore comes
from open-pit mines. Open-Pit Mining: Bulldozers and other equipment remove the soil
and rocks that cover the iron ore deposit and then explosives break up the mass of ore
into smaller pieces. Once mined, the iron ore is transported to processing plants where it
is broken down, separated from sand, and washed. The iron is also separated from the
ore.

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Figure 2.2(a): Iron ore mining

b .c
Figure 2.2:(b) Aeria view of National Iron ore Mining Company, Itakpe; and (c) Agbaja Iron
Ore Project, Kogi - Mining Technology

Blast Furnace Process


A blast furnace is a steel cylinder lined with refractory. It operates continuously until the
lining wears out, which takes many years to occur. The term blast furnace comes from
the blast of hot air that is blown into the lower part of the furnace at between 1400º to
2100ºF (760-1149 ºC).

Molten iron is produced in a blast furnace by the following steps:


1. Charge (solid iron ore, coke, and limestone) is constantly dumped into the top of the
furnace.
2. A blast of hot air is blown into the furnace from the bottom.
3. Coke is the fuel that supplies additional heat, increasing the temperature of the charge.
4. Chemical reactions occur: coke reacts with oxygen from the air, creating the reducing
agent (carbon monoxide), which removes oxygen from the ore.
5. Limestone reacts with impurities in the furnace, forming slag, which floats to the top of
the furnace vessel.
6. Every hour or so the molten iron is removed and sent on for further processing.

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Figure 2.3: (a) Blast Furnace Process layout

b c d
Figure 2.3: (b) Old Blast Furnace stock, (c) ThomasSaupe/Getty Images (Hydrogen
powered Steel Blast Furnace plant), (d) Former AHM blast furnace in Port of Sagunt,
Valencia, Spain

Extraction of Iron from Iron ore (Hematite)


To convert iron ore into metallic iron, oxygen and impurities must be removed. This
process requires heat and a reducing agent, a substance that combines with the oxygen
and releases it from the ore.
Iron is extracted in a large container called a blast furnace from its ore, hematite (Fe2O3).
Modern blast furnaces produce approximately 10,000 tonnes of iron per day. The
process is demonstrated and explained below;
:

Blast furnace placed in an installation


1. Iron ore + limestone sinter

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2. Coke
3. Elevator
4. Feedstock inlet
5. Layer of coke
6. Layer of sinter pellets of ore and
limestone
7. Hot blast (around 1200°C)
8. Removal of slag
9. Tapping of molten pig iron
10. Slag pot
11. Torpedo car for pig iron Figure 2.4:Blast furnace installation
12. Dust cyclone for separation of solid particles
13. Cowper stoves for hot blast
14. Smoke outlet (can be redirected to carbon capture & storage (CCS) tank)
15: Feed air for Cowper stoves (air pre-heaters)
16. Powdered coal
17. Coke oven
18. Coke
19. Blast furnace gas downcomer

Blast furnace diagram


1. Hot blast from Cowper stoves
2. Melting zone (bosh)
3. Reduction zone of ferrous oxide (barrel)
4. Reduction zone of ferric oxide (stack)
5. Pre-heating zone (throat)
6. Feed of ore, limestone, and coke
7. Exhaust gases
8. Column of ore, coke and limestone
9. Removal of slag
10. Tapping of molten pig iron
11. Collection of waste gases

Chemistry of Extraction of Iron in Blast furnaceFigure 2.5: Blast furnace parts


The raw materials for the extraction include: iron ore (hematite), coke (an impure form of
carbon), and limestone added into the top of the blast furnace. Hot air is blown into the
bottom.

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Figure 2.6: Diagram showing the carbon extraction of iron

Some of the chemical reactions occurring in the zones of the blast furnace
Zone 1:
Coke burns in the hot air forming carbon dioxide
The reaction is exothermic so it gives off heat, heating the furnace
carbon + oxygen => carbon dioxide
The burning of carbon (coke) to provide heat and produce carbon dioxide:
C (s) + O2 (g) => CO2 (g)

Zone 2:
At the high temperatures in the furnace, more coke reacts with carbon dioxide forming
carbon monoxide
carbon + carbon dioxide => carbon monoxide
CO2 (g) + C (s) => 2CO (g)

Zone 3:
Carbon monoxide reduces the iron(III) oxide in the iron ore to form iron
This will melt and collect at the bottom of the furnace, where it is tapped off:
Iron (III) oxide + carbon monoxide => iron + carbon dioxide
The reduction of iron(III) oxide by carbon monoxide:
Fe2O3 (s) + 3CO (g) => 2Fe (I) + 3CO2 (g)

Limestone (calcium carbonate) is added to the furnace to remove impurities in the ore.
The calcium carbonate in the limestone thermally decomposes to form calcium oxide
calcium carbonate => calcium oxide + carbon dioxide
CaCO3 (s) => CaO (s) + CO2 (g)

The calcium oxide formed reacts with the silicon dioxide, which is an impurity in the iron
ore, to form calcium silicate. This melts and collects as a molten slag floating on top of
the molten iron, which is tapped off separately
calcium oxide + silicon dioxide => calcium silicate
CaO (s) + SiO2 (s) => CaSiO3 (l)

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