The document discusses the production of ferrous metals like iron and steel. It begins with an overview of the three main ingredients - iron ore, coke, and limestone - that are fed into a blast furnace to produce molten iron or pig iron. The pig iron can then undergo further processing through cupola furnaces or Bessemer converters to produce cast iron or steel. Continuous casting is also discussed, which involves pouring the molten metal directly into molds to produce shapes like blooms, slabs, and billets.

1. 1
Mechanical Engineering TechnologyMechanical Engineering Technology
The Production of Ferrous MetalsThe Production of Ferrous Metals
At the end of the lesson students should
be able to:
1. Define the three main ingredients used in
the production of iron and steel.
2. Draw and explain the diagram of
production of iron and steel (ferrous
metals).
3. Define other processes involved in the
production process.
4. List the end products of iron and steel.

2. The Production of Iron & Steel.The Production of Iron & Steel.
The importance of metals to man in today's world cannot
be overemphasized because we use them in our everyday
life.
Metals are divided into three main groups;
Ferrous,
Non-ferrous
Alloys.
2

3. Non-Ferrous MetalsNon-Ferrous Metals
These contain little or no iron and they
do not rust when exposed to air.
3
These contain mainly iron and theyThese contain mainly iron and they
rust easily when exposed to air.rust easily when exposed to air.

4. REVIEW OF PRODUCTION OF IRONREVIEW OF PRODUCTION OF IRON
AND STEELAND STEEL
4
Production of iron & steel begins in a blast furnace.

5. REVIEW OF PRODUCTION OF IRONREVIEW OF PRODUCTION OF IRON
AND STEELAND STEEL
5
The “Charge” is fed into the furnace.
Iron oreIron ore
CokeCoke
LimestoneLimestone

6. REVIEW OF PRODUCTION OF IRONREVIEW OF PRODUCTION OF IRON
AND STEELAND STEEL
6
The coke is burned as aThe coke is burned as a
fuel to heat the furnacefuel to heat the furnace ..
The iron ore melts and formsThe iron ore melts and forms
molten iron called pig ironmolten iron called pig iron..
The limestone melts & acts asThe limestone melts & acts as
a flux that collects thea flux that collects the
impurities given offimpurities given off
during the smelting process.during the smelting process.

7. REVIEW OF PRODUCTION OF IRON AND STEELREVIEW OF PRODUCTION OF IRON AND STEEL
7
MoltenMolten
metalmetal
BlastBlast
furnacefurnace
CokeCoke
Iron oreIron ore
LimestoneLimestone
ContinuousContinuous
CastingCasting
ElectricElectric
ArcArc
FurnaceFurnace
CupolaCupola
FurnaceFurnace
AlloyAlloy
SteelsSteels
Cast ironCast iron
II
NN
GG
OO
TT
SS
SOAKINGSOAKING
PITSPITS
Other processingOther processing

8. The Production of Ferrous MetalsThe Production of Ferrous Metals
8
Blast FurnaceBlast Furnace
Pig IronPig Iron
Cupola FurnaceCupola Furnace Puddling FurnacePuddling Furnace Bessemer ConverterBessemer Converter
Cast IronCast Iron Wrought IronWrought Iron Mild SteelMild Steel
Iron oreIron ore
LimestoneLimestone
cokecoke

9. CASTINGCASTING

Process of pouring hot
liquid metal into a
mould.
Upon solidification the
metal takes the shape
of the mould.
9

10. CONTINUOUS CASTINGCONTINUOUS CASTING
10

11. PRODUCTS FROM CONTINUOUS CASTINGPRODUCTS FROM CONTINUOUS CASTING
11

12. PRODUCTS FROM CONTINUOUS CASTINGPRODUCTS FROM CONTINUOUS CASTING
12

13. LET’S REVIEWLET’S REVIEW
 Production of iron and steel begins in a
______________ ____________
 The ingredients placed in the furnace are
__________ __________
________
Cast iron is the product of the _______furnace
13
blast furnaceblast furnace
coke iron ore limestonecoke iron ore limestone
cupolacupola

14. LET’S REVIEWLET’S REVIEW
 __________ __________ called pig
iron is drawn from the blast furnace and
taken for further processing.
 The pouring of liquid metals into moulds
is referred to as ________________.
Continuous casting, casts directly into
shapes such as __________
_________ ________.
14
Molten metalMolten metal
castingcasting
blooms slabs billetsblooms slabs billets

15. REFERENCESREFERENCES
15
http://www.britannica.com/eb/article-81416 Reviewed July 12, 2006
http://en.wikipedia.org/wiki/Continuous_Casting Reviewed July 12, 2006
http://frisch-gmbh.de/images/stranggiessen.jpg Reviewed July 14, 2006
http://www.me.gatech.edu/jonathan.colton/me4210/flowline1.gif Reviewed July 14, 2006
http://www.amk.al.lg.ua/images/diagram.jpg Reviewed July 15, 2006
http://www.schoolscience.co.uk/content/4/chemistry/steel/images/slabbb.gif
Reviewed July 15, 2006
Kozak, Bruce., Dzierzawski , Joseph. , SMS Demag http://www.steel.org
Reviewed July 19, 2006