STEEL FROM IRON ORE (PIG IRON)

Pig iron is the basic material from which, wrought iron and steels are produced. It is obtained by smelting (chemical reduction) of iron ore in the blast furnace. In addition to iron, Pig iron contains varying quantities of other elements such as carbon, silicon, manganese, sulphur and phosphorus. These may amount to as much as 10% of the weight and 25% of the volume of pig iron.
Pig iron is obtained by smelting (chemical reduction) of iron ore in the blast furnace.
The basic materials used for the manufacture of pig iron are iron ore, coke, and limestone. The coke is burned as a fuel to heat the furnace; as it burns, the coke gives off carbon monoxide, which combines with the iron oxides in the ore, reducing them to metallic iron. This is the basic chemical reaction in the blast furnace;
It has the equation: Fe2O3 + 3CO = 3CO2 + 2Fe.
The limestone in the furnace charge is used as an additional source of carbon monoxide and as a “flux” to combine with the infusible silica present in the ore to form fusible calcium silicate. Without the limestone, iron silicate would be formed, with a resulting loss of metallic iron. Calcium silicate plus other impurities form a slag that floats on top of the molten metal at the bottom of the furnace. Ordinary pig iron produced by blast furnaces contains about 92% Iron, 3 to 4% carbon, 0.5 to 3% silicon, 0.25 to 2.5% manganese, 0.04 to 2% phosphorus and a trace of sulphur.

•    INTRODUCTION
•    CLASSIFICATION OF PIG IRON
•    USES AND APPLICATION
•    B.I.S. SPECIFICATION
•    MARKET SURVEY
•    PROCESS FLOW CHART
•    MANUFACTURING PROCESS OF PIG IRON
•    RAW MATERIAL CHARACTERISTICS
•    PROCESS OF SINTERING
•    DIFFERENT ZONES OF BLAST FURNACE
•    CASTING PROCESS OF PIG IRON
•    QUALITY CONTROL
•    PLANT LAYOUT
•    SUPPLIERS OF PLANT AND MACHINERY
•    SUPPLIERS OF RAW MATERIALS
APPENDIX – A:
1.      COST OF PLANT ECONOMICS
2.      LAND & BUILDING
3.      PLANT AND MACHINERY
4.      FIXED CAPITAL INVESTMENT
5.      RAW MATERIAL
6.      SALARY AND WAGES
7.      UTILITIES AND OVERHEADS
8.      TOTAL WORKING CAPITAL
9.      COST OF PRODUCTION
10.      PROFITABILITY ANALYSIS
11.      BREAK EVEN POINT
12.      RESOURCES OF FINANCE
13.      INTEREST CHART
14.      DEPRECIATION CHART
15.      CASH FLOW STATEMENT
16.      PROJECTED BALANCE SHEET