You may use the USGS minerals website (http://minerals.usgs.gov/minerals/), Wiki
ID: 1713191 • Letter: Y
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You may use the USGS minerals website (http://minerals.usgs.gov/minerals/), Wikipedia or other web sources to answer the following questions. Make sure to document the references you use. You may NOT cut and paste directly from web sources without proper attribution - paraphrase the information using your own words or use proper citations. 1. Investigate the mining and processing of iron ore used to make steel. a. Where is iron mined in the U.S.? b. What is the typical percentage of iron in iron ore mined in the U.S.? c. Approximately how many kg of iron ore do you need to make 1 kg of iron for use irn steel manufacture? How is iron ore processed for use in making steel? d. 2. Investigate the mining and processing of carbon used to make steel. (Hint: see wikipedia Approximately how many kg of coal do you need to make 1 kg of coke for use in steel manufacture? a. b. How is coke made? 3. Molybdenum is an alloying element used in steel to enhance its properties. How is molybdenum mined? Hint: see (http://www.imoa What is the typical percentage of molybdenum in molybdenum deposits mined in the U.S.? Approximately how many kg of molybdenum ore do you need to make 1 kg of molybdenum for use in steel manufacture? How is the molybdenum ore processed to make the molybdenum used in steel? a. i-mining-processing.ph nfo/molybdenum/molybdenum b. c. d. 4. How is steel made? Approximately how much energy is required to make 1 kg of steel? 5. Approximately how much steel is produced/used annually in the U.S.? 6. What are the environmental effects of manufacturing steel?Explanation / Answer
1)a) Iron ore is mined from 9 active mines and 3 reclamation operations in Michigan, Minnesota and Utah. Most of Iron ore is mined in Northern Minnesota's Mesabi range.
1)b) Iron itself is found in Iron ore in the form of Magnetite of about 72.4%. Ores containing high quantities of Hematite or Magnetite ( greater than 60%) are known as Natural ore or Direct Shipping ore meaning they can be fed directly into Iron making blast furnaces.
1)c) About 1.6 kg of Iron ore is used to manufacture 1 kg of Iron.
1)d) Steel making process starts with processing of Iron ore. The rock containing Iron ore is ground and the ore is extracted using Magnetic rollers. Fine grained Iron ore is processed into Coarse grained clumps for use in Blast Furnace. Coal is cleaned of impurities in a Coke furnace yielding an almost pure form of Carbon. A mixture of Iron ore and Coal is then heated in a Blast Furnace to produce Molten Iron or Pig Iron from which Steel is made.
2)a) For every 1 kg of Coke produced, about 1.6 kg of Coal is used.
2)b) Volatile constituents of Coal including Water, Coal-gas,Coal-tar are driven off by baking in an airless furnace or Oven at temperatures as high as 2000 deg.celsius but usually around 1000 to 1100 deg.celsius. This fuses together the Carbon and residual ash. Some facilities have by product cooking ovens in which the Volatile hydrocarbons are mainly used after purification a separate combustion process to generate energy. Non by product cooking furnaces or Coke furnaces burn hydrocarbon gases produced by Coke making process to drive Carbonization process.
3)a) Molybdenum and Copper-Molybdenum porphyries are mined by open pit or by underground methods. Once the ore has been crushed and ground, the metallic minerals are then separated from gangue minerals or the molybdenum and copper from each other by flotation processes using a wide variety of reagents.
3)b) Primary deposits containing between 0.1 and 0.5 percent molybdenum are extensive. Copper porphyries also are very large deposits, but their molybdenum content varies between 0.005 and 0.05 percent. Roughly 40 percent of molybdenum comes from primary mines, with the other 60 percent a by product of copper.
3)c) Around 1.6 to 1.7 kg of Molybdenum ore is required to make 1 kg of Molybdenum for use in Steel.
3)d) Processing of Molybdenum ore follows process as follows: 1) Mined ore 2) Crushing 3) Grinding 4) Flotation 5) Leaching 6) Roasting 7) Smelting.
4) To make steel, iron ore is first mined from the ground. It is then smelted in blast furnaces where the impurities are removed and carbon is added. In fact, a very simple definition of steel is "iron alloyed with carbon, usually less than 1%".
Roughly 20 to 50 MJ of energy is used to make 1 kg of Steel.
5) Around 88 to 100 Million tonnes of Steel is produced annually in U.S
6) It has a number of impacts on environment like air emissions of CO, SOX, NOX, PM2, waste water contaminants, hazardous waste and solid wastes. Virtually all of Greenhouse gases emissions are associated with Steel production are from CO2 emissions related to energy consumption. Air emissions such as Coke oven gas, Naphthalene, Ammonium compounds, Crude light oil, Sulfur and Coke Dust. Contamination of water and wastes from Electric arc furnaces.
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