How is pig iron converted into cast iron?

CAST IRON IS MADE FROM PIG IRON BY MELTING PIG IRON WITH IRON SCRAP AND COKE AND BY PASSING HOT AIT BLAST INTO THE MIXTURE. CAST IRON HAS 3% CARBON CONTENT LOWER THAN PIG IRON. CAST IRON IS HARD AND BRITTLE.

Is pig iron and cast iron the same?

Difference between pig iron and cast iron

The iron obtained from blast furnace is called pig iron. It contains about 4% carbon and many other impurities like S,P,Si,Mn etc. Cast, iron, on the other hand, is made by melting pig iron with scrap iron and coke using hot air blast.

What is pig iron converted into?

It has oftentimes been a subject of remark that wrought iron tubes employed in the production of sodium are never converted into cast iron, although the carbonate of soda from which sodium is distilled contains a large amount of carbon.

How is molten pig iron converted into steel?

Basic oxygen steelmaking is a primary steelmaking process for converting molten pig iron into steel by blowing oxygen through a lance over the molten pig iron inside the converter. Exothermic heat is generated by the oxidation reactions during blowing.

How do you remove carbon from pig iron?

To reduce the carbon content in pig iron and obtain the desired carbon content of steel, the pig iron is re-melted and oxygen is blown through in a process called basic oxygen steelmaking, which occurs in a ladle.

Cast iron|Pig iron|lect-8|Metallurgy|Wrought iron|Pig iron into steel |Cast iron into wrought iron|

How does a BOF work?

The process is known as the basic oxygen furnace process, basic oxygen steelmaking, or the oxygen converter process. During the process, oxygen is blown into a BOF converter containing liquid hot metal containing high carbon content. The oxygen combines with the dissolved carbon to form CO, which then escapes as gas.

How pig iron is extracted from its ore?

Pig iron is produced by smelting or iron ore in blast furnaces or by smelting ilmenite in electric furnaces. Pig iron is supplied in a variety of ingot sizes and weights, ranging from 3 kg up to more than 50 kg.

How is cast iron obtained?

It is made by reducing iron ore in a blast furnace. The liquid iron is cast, or poured and hardened, into crude ingots called pigs, and the pigs are subsequently remelted along with scrap and alloying elements in cupola furnaces and recast into molds for producing a variety of products.

How does the Bessemer process work?

The bessemer process reduces molten pig iron in so-called bessemer converters—egg-shaped, silica, clay, or dolomite-lined containers with capacities of 5 to 30 tons of molten iron. An opening at the narrow upper portion of the bessemer converter allows iron to be introduced and the finished product to be poured out.

Why does pig iron not rust?

Cast iron is an alloy with a high carbon content (at least 1.7% and usually 3.0–3.7%), making it relatively resistant to corrosion.

Can pig iron be welded?

It is possible to weld cast iron, but it needs to be done using the correct techniques and with care to avoid cracking. Most welding methods require the surface of the material to be cleaned and cast iron benefits from pre and post-weld heating as well as careful cooling.

Which is the purest form of iron?

Wrought Iron is the purest form of iron.

How does a Bessemer converter refine steel?

The Bessemer process was the first inexpensive industrial process for the mass production of steel from molten pig iron before the development of the open hearth furnace. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron.

What happens in Bessemer converter?

The Bessemer converter was a machine and surrounding process that involved the removal of impurities from pig iron (a type of iron with a high carbon content) and its conversion into steel – a material that had historically been costly and time consuming to manufacture.

How did Bessemer process improve manufacturing?

The Bessemer Process was the first inexpensive industrial process that allowed for the mass production of steel. Before the development of an open-mouth furnace, the process used a molten pig iron to melt iron. The real difference with this process was that air was forced through the molten iron to remove impurities.

Which furnace is used to get pig iron from iron ore?

Blast furnaces are used to produce pig iron from iron ore for subsequent processing into steel, and they are also employed in processing lead, copper, and other metals.

Why is it called cast iron?

It's called “cast iron” because it's made through casting. To produce cast iron, metalworking companies smelt raw iron or pig iron. Once smelted, the molten iron is mixed with carbon and other alloys.

What is raw material for cast iron?

Cast iron is made from pig iron, which is the product of melting iron ore in a blast furnace. Cast iron can be made directly from the molten pig iron or by re-melting pig iron, often along with substantial quantities of iron, steel, limestone, carbon (coke) and taking various steps to remove undesirable contaminants.

How is iron extracted step by step?

Iron is extracted from iron ore in a huge container called a blast furnace. Iron ores such as haematite contain iron(III) oxide, Fe ₂O ₃. The oxygen must be removed from the iron(III) oxide in order to leave the iron behind. Reactions in which oxygen is removed are called reduction reactions.

What is the smelting process?

Smelting is a form of extractive metallurgy to produce a metal from its ore. Smelting uses heat and a chemical reducing agent to decompose the ore, driving off other elements as gasses or slag and leaving just the metal behind. The reducing agent is commonly a source of carbon such as coke, charcoal, and coal.

What is the difference between BOF and EAF?

The key difference between the routes is the type of raw materials they consume. For the BF-BOF route these are predominantly iron ore, coal, and recycled steel, while the EAF route produces steel using mainly recycled steel and electricity.

What are the main chemical processes that take place in the BOF during steel making?

It plays a predominant role in integrated steel plants for the production of crude steel. The process involves blowing oxygen (O2) through HM with the help of a top lance to reduce its carbon (C) content by oxidation. At present mixed blowing is adopted in the BOS process which was developed in the late 1970s.

How much oxygen does a BOF use?

Service life of oxygen lance is about 400 heats. The bottom blown basic oxygen furnace is equipped with 15-20 tuyeres for injection of oxygen or lime powder containing oxygen. In this process, the tuyeres are cooled by either hydrocarbon gas or oil supplied to the outer jacket of the tube.

What does a Bessemer converter look like?

Bessemer process

The Bessemer converter is a cylindrical steel pot approximately 6 metres (20 feet) high, originally lined with a siliceous refractory. Air is blown in through openings (tuyeres) near the bottom, creating oxides of silicon and manganese, which become part of the slag, and of carbon, which…