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Explain smelting process.
Smelting process (in a Blast Furnace):
Smelting is an energy intensive process used to .
The charge, made of roasted ore, coke, and in the proportions of \(8\):\(4\):\(1\), is melted in a blast furnace by introducing it through the top hopper arrangement.
There are three essential regions in the furnace:
a. The Lower Region (Combustion Zone):
In this region the temperature has reached \(1500\)°C. Here, to form \(CO_2\) when the charge (solid iron ore, coke, and limestone) comes in contact with a hot blast of air.
\(C\) + \(O_2\) → \(CO_2\) + Heat.
It is an because heat is released.
b. The Middle Region (Fusion Zone):
In this region the temperature is around \(1000\)°C, here \(CO_2\) is converted to \(CO\).
\(CO_2\) + \(C\) → \(2CO\) - Heat.
Limestone decomposes to and \(CO_2\).
\(CaCO_3\) → \(CaO\) + \(CO_2\) - Heat.
The above two reactions are due to the absorption of heat.
Calcium oxide bind with silica to form calcium silicate slag.
\(CaO\) + \(SiO_2\) →
c. The Upper Region (Reduction Zone):
In this region the temperature is \(400\)°C, here carbon monoxide reduces ferric oxide to form a relatively pure .
\(Fe_2O_3\) + 3\(CO\) → \(2Fe\) + \(3CO_2\)
After the remo val of slag, the molten iron is collected at the bottom of the furnace. This process formed iron is called .
It is remelted and cast into various moulds. This iron is known as .
It is remelted and cast into various moulds. This iron is known as .
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