EXTRACTION OF IRON

INTRODUCTION

Iron is extracted from its oxide ore called HAEMATITE (Fe2O3).

PRINCIPLE OF EXTRACTION

Extraction of iron is based on the reduction of HAEMATITE (Fe2O3) with carbon..

DETAILS OF EXTRACTION

The process of the extraction of iron is carried out by the following steps:

Concentration of ore

Calcination or Roasting of ore

Reduction of ore

Concentration of ore:

In this metallurgical operation, the ore is concentrated by removing impurities like soil etc. The

process involves the crushing and washing of ore.

Calcination or Roasting of ore:

The concentrated ore is now heated in the presence of air. The process of roasting is performed to
remove moisture, CO2, impurities of sulphur, arsenic. Ferrous oxide is also oxidized to ferric oxide.

Reduction of ore
 The process of reduction is carried out in a blast furnace.

Blast Furnace

The blast furnace is a cylindrical tower like structure about 25m to 35m high. It has an outer shell of
steel. Inside of furnace is lined with fire bricks. The top of the furnace is closed by a cup-cone feeder.

The charge

The charge consists of :

roasted ore

Coke

Limestone

Details of reduction

The charge is fed into the furnace from its top. A preheated blast of air at 1500OC, is blown into
the furnace under pressure near to the bottom. The blast oxidizes carbon to CO2.

C + O2 CO2 + heat

Formation of CO2 is an exothermic reaction in which a huge amount of heat is liberated which rises the
temperature to 1900OC in this region. As the CO2 passes upwards, it reacts more coke to form carbon
monoxide.

CO2 + C 2CO + heat

Formation of CO is an endothermic reaction and the temperature in this region falls to 1100OC. CO
is the main reducing agent in the upper portion of blast furnace.

Reactions in blast furnace

Fe2O3 + 3C 2Fe + 3CO

Fe3O4 + 4CO 3Fe + 4CO2

CO2 + C 2CO

Overall reaction

Fe2O3 + 3CO 2Fe + 3CO2

The liquid iron runs downward to the bottom of the furnace and is withdrawn through tap hole.

Slag formation

Lime stone on heating decomposes to CaO and CO2.

CaCO3 CaO + CO2

CaO now reacts the impurities of ore called GANGUE to form slag. Slag is the mixture of CaSiO3

and Ca(AlO2)2. The slag floats over the top of molten iron. Slag is a useful byproduct. It is used

in road making, cement manufacturing a light weight building materials.

Flux + Gangue Slag

CaO + SiO2 CaSiO3

CaO + Al2O3 Ca(AlO2)2