Cast ironCast iron is a class of iron–carbon alloys with a carbon content more than 2%. Its usefulness derives from its relatively low melting temperature. The alloy constituents affect its color when fractured; white cast iron has carbide impurities which allow cracks to pass straight through, grey cast iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material breaks, and ductile cast iron has spherical graphite "nodules" which stop the crack from further progressing.
Iron oreIron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, or deep purple to rusty red. The iron is usually found in the form of magnetite (Fe3O4, 72.4% Fe), hematite (Fe2O3, 69.9% Fe), goethite (FeO(OH), 62.9% Fe), limonite (FeO(OH)·n(H2O), 55% Fe) or siderite (FeCO3, 48.2% Fe). Ores containing very high quantities of hematite or magnetite, typically greater than about 60% iron, are known as natural ore or direct shipping ore, and can be fed directly into iron-making blast furnaces.
BloomeryA bloomery is a type of metallurgical furnace once used widely for smelting iron from its oxides. The bloomery was the earliest form of smelter capable of smelting iron. Bloomeries produce a porous mass of iron and slag called a bloom. The mix of slag and iron in the bloom, termed sponge iron, is usually consolidated and further forged into wrought iron. Blast furnaces, which produce pig iron, have largely superseded bloomeries. A bloomery consists of a pit or chimney with heat-resistant walls made of earth, clay, or stone.
SlagSlag is a by-product of smelting (pyrometallurgical) ores and recycled metals. Slag is mainly a mixture of metal oxides and silicon dioxide. Broadly, it can be classified as ferrous (by-products of processing iron and steel), ferroalloy (by-product of ferroalloy production) or non-ferrous/base metals (by-products of recovering non-ferrous materials like copper, nickel, zinc and phosphorus). Within these general categories, slags can be further categorized by their precursor and processing conditions (e.g.
SmeltingSmelting is a process of applying heat to an ore, to extract a base metal. It is a form of extractive metallurgy. It is used to extract many metals from their ores, including silver, iron, copper, and other base metals. Smelting uses heat and a chemical- reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal base behind. The reducing agent is commonly a fossil fuel source of carbon, such as coke—or, in earlier times, charcoal.
Pig ironPig iron, also known as crude iron, is an intermediate good used by the iron industry in the production of steel, which is developed by smelting iron ore in a blast furnace. Pig iron has a high carbon content, typically 3.8–4.7%, along with silica and other constituents of dross, which makes it brittle and not useful directly as a material except for limited applications. The traditional shape of the molds used for pig iron ingots is a branching structure formed in sand, with many individual ingots at right angles to a central channel or "runner", resembling a litter of piglets being nursed by a sow.
Wrought ironWrought iron is an iron alloy with a very low carbon content (less than 0.05%) in contrast to that of cast iron (2.1% to 4%). It is a semi-fused mass of iron with fibrous slag inclusions (up to 2% by weight), which give it a wood-like "grain" that is visible when it is etched, rusted, or bent to failure. Wrought iron is tough, malleable, ductile, corrosion resistant, and easily forge welded, but is more difficult to weld electrically.
BellowsA bellows or pair of bellows is a device constructed to furnish a strong blast of air. The simplest type consists of a flexible bag comprising a pair of rigid boards with handles joined by flexible leather sides enclosing an approximately airtight cavity which can be expanded and contracted by operating the handles, and fitted with a valve allowing air to fill the cavity when expanded, and with a tube through which the air is forced out in a stream when the cavity is compressed.
Coke (fuel)Coke is a grey, hard, and porous coal-based fuel with a high carbon content and few impurities, made by heating coal or oil in the absence of air—a destructive distillation process. It is an important industrial product, used mainly in iron ore smelting, but also as a fuel in stoves and forges when air pollution is a concern. The unqualified term "coke" usually refers to the product derived from low-ash and low-sulphur bituminous coal by a process called coking.
SteelSteel is an alloy of iron and carbon with improved strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels, which are resistant to corrosion and oxidation, typically need an additional 11% chromium. Because of its high tensile strength and low cost, steel is used in buildings, infrastructure, tools, ships, trains, cars, bicycles, machines, electrical appliances, furniture, and weapons. Iron is the base metal of steel.
SteelmakingSteelmaking 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. Steelmaking has existed for millennia, but it was not commercialized on a massive scale until the mid-19th century. An ancient process of steelmaking was the crucible process.
CharcoalCharcoal is a lightweight black carbon residue produced by strongly heating wood (or other animal and plant materials) in minimal oxygen to remove all water and volatile constituents. In the traditional version of this pyrolysis process, called charcoal burning, often by forming a charcoal kiln, the heat is supplied by burning part of the starting material itself, with a limited supply of oxygen. The material can also be heated in a closed retort. Modern "charcoal" briquettes used for outdoor cooking may contain many other additives, e.
Water wheelA water wheel is a machine for converting the energy of flowing or falling water into useful forms of power, often in a watermill. A water wheel consists of a wheel (usually constructed from wood or metal), with a number of blades or buckets arranged on the outside rim forming the driving car. Water wheels were still in commercial use well into the 20th century but they are no longer in common use. Uses included milling flour in gristmills, grinding wood into pulp for papermaking, hammering wrought iron, machining, ore crushing and pounding fibre for use in the manufacture of cloth.
Newcomen atmospheric engineThe atmospheric engine was invented by Thomas Newcomen in 1712, and is often referred to as the Newcomen fire engine (see below) or simply as a Newcomen engine. The engine was operated by condensing steam drawn into the cylinder, thereby creating a partial vacuum which allowed the atmospheric pressure to push the piston into the cylinder. It was historically significant as the first practical device to harness steam to produce mechanical work. Newcomen engines were used throughout Britain and Europe, principally to pump water out of mines.
Industrial RevolutionThe Industrial Revolution, also known as the First Industrial Revolution, was a period of global transition of human economy towards more efficient and stable manufacturing processes that succeeded the Agricultural Revolution, starting from Great Britain, continental Europe, and the United States, that occurred during the period from around 1760 to about 1820–1840. This transition included going from hand production methods to machines; new chemical manufacturing and iron production processes; the increasing use of water power and steam power; the development of machine tools; and the rise of the mechanized factory system.
Electric arc furnaceAn electric arc furnace (EAF) is a furnace that heats material by means of an electric arc. Industrial arc furnaces range in size from small units of approximately one-tonne capacity (used in foundries for producing cast iron products) up to about 400-tonne units used for secondary steelmaking. Arc furnaces used in research laboratories and by dentists may have a capacity of only a few dozen grams. Industrial electric arc furnace temperatures can reach , while laboratory units can exceed .
MetallurgyMetallurgy is a domain of materials science and engineering that studies the physical and chemical behavior of metallic elements, their inter-metallic compounds, and their mixtures, which are known as alloys. Metallurgy encompasses both the science and the technology of metals; that is, the way in which science is applied to the production of metals, and the engineering of metal components used in products for both consumers and manufacturers. Metallurgy is distinct from the craft of metalworking.
Countercurrent exchangeCountercurrent exchange is a mechanism occurring in nature and mimicked in industry and engineering, in which there is a crossover of some property, usually heat or some chemical, between two flowing bodies flowing in opposite directions to each other. The flowing bodies can be liquids, gases, or even solid powders, or any combination of those. For example, in a distillation column, the vapors bubble up through the downward flowing liquid while exchanging both heat and mass.
Open hearth furnaceAn open-hearth furnace or open hearth furnace is any of several kinds of industrial furnace in which excess carbon and other impurities are burnt out of pig iron to produce steel. Because steel is difficult to manufacture owing to its high melting point, normal fuels and furnaces were insufficient for mass production of steel, and the open-hearth type of furnace was one of several technologies developed in the nineteenth century to overcome this difficulty.
Reverberatory furnaceA reverberatory furnace is a metallurgical or process furnace that isolates the material being processed from contact with the fuel, but not from contact with combustion gases. The term reverberation is used here in a generic sense of rebounding or reflecting, not in the acoustic sense of echoing. Chemistry determines the optimum relationship between the fuel and the material, among other variables.
