Steel Production

Question 1

Where is Iron ore found?

Answer 1

The earths crust.

Question 2

What percentage of iron ore is pure iron?

Answer 2

50-70%

Question 3

What is the gold mine of iron ore in that it contains the highest possible iron ore percentage?

Answer 3

Hematite

Question 4

What are the four steps in Modern Steel Manufacturing?

Answer 4

1. Mine
2. Blast furnace
3. Refinement
4. Steel Formation

Question 5

In the blast furnace what three materials are mixed and heated? What do these materials form?

Answer 5

Iron ore, Coke, and limestone are heated to form pig iron

Question 6

What is the purpose of the coke in the blast furnace?

Answer 6

Supply heat and carbon monoxide to reduce the iron

Question 7

What is the purpose of the limestone in the blast furnace?

Answer 7

Removes impurities (Silica and Alumina) from the ore.
Slag floats on top of the molten pig iron.

Question 8

Pig Iron has a ___ carbon content. What is its range?

Answer 8

high, 4-5%

Question 9

What is the matter with this pig iron? Why can’t it be used as a structural material?

Answer 9

It is very hard and brittle because of the high carbon content.

Question 10

What are the two types of Refinement processes?

Answer 10

Basic oxygen furnace

Electric Arc

Question 11

What happens during the Basic oxygen refinement process?

Answer 11

Add scrap, Add pig iron, blow with oxygen, pour molten steel, dispose slag

Question 12

What is the purpose of the limestone in the basic oxygen refinement process?

Answer 12

To reduce the sulphur and phosphorus levels

Question 13

What are the three materials added in the refinement process?

Answer 13

Limestone, scrap metal, pig iron

Question 14

What happens in the electric arc furnace?

Answer 14

electrodes supply high current and heat to melt and refine the steel. Tap the same way.

Question 15

Steel can be casted into small blocks and shipped to rolling mills where they can be rolled to different sizes. What are these blocks called?

Answer 15

ingots

Question 16

Steel can also be continuously casted what happens during this process?

Answer 16

Pour steel down water cooled mold, solidifies as it travels down through cooling chamber and then it is cut as desired.

Question 17

What are the different cuts

Answer 17

1. Ingot (classic metal chunk)
2. Slab (sidewalk style)
3. Billet ( thin bar)
4. Bloom (big bar)

Question 18

Ingots, Billets, and slabs are rolled to make flat rolled products to make…

Answer 18

plates sheets bars

Question 19

What happens in hot rolling of steel?

Answer 19

Big blooms are passed through rolls with the REVERSE of the desired shape to make structural members.

Question 20

Cold forming causes ____ that increases ____ but reduces ____.

Answer 20

Cold forming causes strain hardening that increases strength and reduces ductility.

Question 21

Strain hardening increases tensile strength by how much?

Answer 21

50-70%