Iron ore grades

Posted by Marf on March 8th, 2011

Iron ore grade:

The concentration of valuable element of interest in a potentially as mined ore is termed as grade of ore. A rock that contains iron compound from which economically iron can be extracted is a iron ore. Grade of ore may vary in its deposit but these variations are not much high. There is a certain grade below which mining and its processing is not beneficial. This is called mine cut off grade. The deposits which contain higher content of metal of interest in their ore are termed as high grade ore deposits.

High grade Iron ore:

The ore which contain higher iron content in it is termed as high grade iron ore. The high grade ore rocks are hematite, magnetite, and goethite/limonite. Most of the high grade iron ore processed in the world is hematite ore. Hematite is economic iron bearing mineral it has largest distribution in the world. Iron content in the hematite is about 69.94 %. It is rare that hematite body does not contain a few percentage of magnetite. Magnetite iron content is higher but it is present in less quantity in the world. Hematite and magnetite deposits mainly present in metamorphosed, sedimentary rocks. Magmatic deposits are the major source of magnetite where the mineral is separate out in a large magma chamber. The largest magmatic deposits are present at Kiruna in Sweden. Examples of high grade iron ore are magnetite, hematite and limonite.

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Economically iron ore deposits are called Banded Iron Formations (BIF). Banded Iron Formations are formed by metamorphosed sedimentary rocks having iron bedded and silica. These are Proterozoic (2500-524 million year old) having deposits of iron oxide on the sea bed in reducing atmosphere. Mining and processing of BIF involves various steps that are coarse grinding, screening, fine grinding and concentrating the grinding material with magnetic separator, leaving quartz as gangue particle. During beneficiation of gangue material unwanted material is separated out and removed as tailing. The largest BIF are Hamersley province in Western Australia and the Lake Superior district USA. Economic deposits of iron mostly those which are enriched by natural processes to grade of 65% iron. Historically, such iron content ore lumps directly feed into smelter form sinter or pellets.

Low grade iron ore:

The ore which contain low iron content in it is termed as Low grade iron ore. It is also called cut off grade ore. Cut off grade ore ranges are 20-30% Fe. Iron ore like Siderite, chamosite, marcasite, pyrite are low grade iron ores. It was main supply iron from centuries of the world’s early history of iron production. Importance of low grade iron ore mining and beneficiation has significantly increased because high grade ore deposits are consuming rapidly. Beneficiation of the low grade iron ore produces concentrate suitable for blast furnace sinter or pallet making. Beneficiation process involves jigging, autogenously grinding, column flotation, high gradient magnetic separator, fine grinding etc.

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Iron ore analysis

Posted by Marf on March 7th, 2011

Iron ore:

Iron bearing minerals from which iron is extracted economically termed as iron ore. Raw ore or as mined ore contain variant amount of ore proper and loose earth material called gangue. Chemically, iron ore present in the form of oxides, carbonates, sulphide and silicates. Commercially iron oxide is most important. Raw Iron ore contains different metals as gangue such as sulphur, phosphorus, manganese, silicon etc. Iron ore is raw material for iron and steel making. Mostly iron ore used for making pig iron.

Iron ore Chemical analysis

Iron is most widely used metal in the world so it has high economical value. The chemical analysis of iron ore is necessary to find iron content in it. Iron content in the ore determine use of particular iron deposits either economical or not. For economical production from blast furnace minimum 55% iron content is needed. In commercial analysis of iron ores the determinations commonly called for are those of iron, phosphorus, silica and manganese. There are many other elements present in it but not always determined, are alumina, lime, magnesia and sulphur. Some ore also contain titanium, nickel, alkalise, chromium, chromium, vanadium, and all contain some combined water.

If the ore is not hygroscopic, the analyses are made on a sample that has been dried for 1 hour at 1000 C to 1050 C and cooled in desiccators. If the ore is not hygroscopic then analyses is made on air dried sample. The results are corrected to the dry basis as indicated by a determination of moisture content in it.

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Chemical analysis procedure

Chemical analysis of iron ore procedure has different step

i) Moisture content

ii) Loss on Ignition

iii) Iron content

Moisture:

Take 2 g of air dried sample to weighed glass stopper bottle or platinum crucible with tightly fitting cover. Dry at 1000 C to 1050 C for 3 to 4 hours. Place a cover on stopper bottle or crucible. Cool in desiccator, tightly cover the crucible or bottle and weigh. The percentage of moisture can be determined by subtracting the final weight from the original weight, and multiply by 50.

Loss on Ignition:

Take 2 g of sample (dried 1000 C to 1050 C) to weighed platinum crucible with tightly fitting cover. Maintain oxidizing atmosphere with gently heating until oxidation takes place, heat for 30 minutes at 10000 C to 11000. Transfer in desiccator and the loss ignition determined by subtracting the final weigh from the original weight and multiply by 50.

Iron content:

Iron content in iron ore always determined by titrating with standard solution of potassium dichromate or potassium permanganate after the ore has been dissolved in hydrochloric acid and the iron reduced by stannous chloride.

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Iron distribution by nature

Posted by Marf on March 7th, 2011

Iron is sixth most abundant element in universe and most abundant metal.Iron is fourth most abundant element in earth crust. Now we divide iron into three types

i) On the earth surface

ii) In the core’s of earth

iii) In space

Iron in space:

Iron occurs in space in different forms. The large amount of iron present on the moon’s surface (0.5%) in the lunar cell. Meteorites contain iron and nickel. Meteoritic iron does not rust quickly in moist atmosphere. Iron nickel meteorites believed to be first material formed in the universe .Meteorites falls on the earth from space and the most part of them consists of iron. It is easily detectable on the surface of snow and ice on Polar Regions. Like other stars and planets contains considerable amount of iron .Mars contain huge amount iron oxide in its crust, so it is red planet.

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Iron in inner core’s of earth:

By nature large amount of iron present in the inner part of earth. As the inner part of earth formed by Mantle, inner and outer Core’s. About two-thirds of the earth’s mass is in the Mantle. Here main constituents are silicates rich in magnesium and iron, but with an increasing proportion of the heavier iron atoms with greater depth into the earth. The inner and outer cores, which are other one third of the earths mass probably consists of iron alloyed with nickel.

Iron on the earth surface:

On the surface of the earth iron occurs in native and compound states. Native iron (uncombined with other elements) found in very small quantities on the surface of earth. Iron with other elements found in number of ores. Iron on the surface of earth exits in the form of oxides, sulphide, carbonates and silicates.

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Iron uses

Posted by Marf on March 7th, 2011

The iron has countless uses. Iron has a shifting position in periodic table. Iron merely found in pure form due to its oxidizing nature. Most of its ores are present in oxidized form. The wide uses of iron are because of its properties which allow it to be mixed with other elements.

Iron for life

Human body requires iron as one of the essential element. Without iron, a mankind cannot live. Carrying of oxygen and completion of different metabolic functions is the major function of iron. Iron is a part of haemoglobin in RBC. Protein and iron are the prominent part of haemoglobin. Iron uses for transportation of oxygen from lungs to other parts of body. For the synthesis of ATP, iron plays a key role, which is the key source of energy for a mankind. Iron insufficiency lead to body weakness and fatigue. Insufficient iron will lead to iron deficiency anaemia. Iron deficiency is levelled by different iron supplements which are obtained from iron poly maltose and iron gluconate.

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Uses of Iron in daily life

Iron ore uses in making steel. There are different kinds of steel. Almost every industry uses steel in different ways. Iron is mixed with other elements like nickel, silicon, chromium and carbon in different ratio. Steel is used due to its pressure and temperature bearing ability. Steel is used in different structures like buildings, bridges, ships, aeroplanes, vehicles and automobile parts also. In cutting and drilling tools, tungsten steel is used.
Wrought iron and cast iron are usually use in homes. Wrought iron and cast iron are less inclined toward tarnish and moulded effortlessly. Wrought iron and cast iron are commonly used for house commodities like making grills, windows, fencing, arbores and trellis. Cast iron is an essential part of our kitchens. Cast iron has ability of uniform heating, which selects it as a first choice for skillets making. A good quality cookware of cast iron lasts for generations. Cast iron is an indispensable part of kitchen items like ovens, cornbread trays, cake panes etc. Many kitchen appliances are made up of stainless steel.

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Industrial Iron Types

Posted by Marf on March 2nd, 2011

Industrial iron types:

There are three important industrial iron types which are listed below

(i) Cast iron or pig iron

(ii) wrought iron

(iii) steel

Cast Iron or Pig Iron:

Cast iron is the family of ferrous alloys with a wide range of properties. Cast iron is called cast because they are proposed to be cast into desired shape instead of being worked in solid state. Cast iron is a general term covering a wide range of basically iron-carbon alloys (2-4 %) all cast to shape, but some treated to provide ductility, while others may show high hardness and corrosion resistance, etc.

It also contains 1-3% Si. Cast iron make excellent casting alloys since they are easily melted are very fluid in the liquid state.

TYPES OF CAST IRON IN MICROSTRUCTURE
There are four different types of iron differentiated from each other by the distribution of carbon in their microstructures.

(i) White Cast Iron

(ii) Gray Cast Iron

(iii) Ductile Cast Iron or nodular or spherulitic graphite cast Iron

(iv) Malleable Cast Iron

(v) High alloy Cast Iron

Wrought Iron:

Wrought iron is the nearly purest form of iron. A commercial iron consisting of slag (iron silicate) fibres entertained in a ferrite matrix. Wrought iron has 0.12-0.25% C and less than 0.5 % S, P and Si as impurities. Wrought iron is invented by Henry Cort by Lancaster. Wrought iron has toughness, weld ability and corrosion resistance.

FORMING OF WROUGHT IRON:

It is formed by three different ways i.e.

1) pudding process

2) Swedish charcoal process

3) American Aston process.

Steel:

An iron base alloy principally containing 0.25-2% C. Initially cast contain Mn and other alloying element. The hardness of steel increases with increasing carbon amount. The carbon forms Cementite (Fe3C) in steel, it dissolved in steel at high temperature and create hardness by formation of martensite on control cooling.

TYPES OF STEEL

1) steel Mild steel

2) Medium steel

3) High carbon steel

4) Tool steel.

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Pure Iron Properties

Posted by Marf on March 1st, 2011

Native iron found in eruptive rocks and masses of meteoric origin. Chemically pure iron produced by reduction of pure iron oxide using hydrogen. Thermal decomposition of ferrous complex such as oxalate, carbonate or nitrate used for production of iron oxide. Different methods for preparing iron are Electro Decomposition of iron salts, or Thermal decomposition of iron carbonyl.

Iron position in periodic table:

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                                                                                                   Properties of iron:

                                                                 

PROPERTY NAME

PROPERTY

Atomic symbol

Fe

Atomic number

26

Appearance

Malleable, ductile, silvery-white metal

Natural isotopes

4

Total isotopes

10

Atomic weight

55.847

Atomic number

26

Group

VIII

Period

4

Block

D

Melting point

1808 k , 1538 °C, 2800 °F

Boiling point

3023 k, 2862 °C, 5182 °F

Density (293k,g cm-3)

7.874

Electronic configuration

[Ar]3d64s2

Electro negativity

1.83a

Metal radius A0

1.26

Ionic radius (A0)

0.61(small spin) 0.78 (high spin)

III

0.55 (small spin) 0.645 (high spin)

Electrical resistivity

(293 k/cm)9.71X10-8

First Ionizing Energy (kJ/mol)

759.1

Third Ionisation Energy (kJ/mol)

2951 kJ.mol -1

Molar volume (cm3)

7.09

Coefficient of linear thermal expansion (k-1)

12.3X10-6

Lattice Structure

Body-Centred Cubic (BCC)

Oxidation States

6, 3, 2, 0, -2

                                                                       

 

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Iron: An Introduction

Posted by Marf on February 28th, 2011


Origin of word iron:

As the title suggest, this article is all about iron history, its origin.It gives brief introduction of iron. Iron is used in our daily life. Iron(element 26) originated its name from the Anglo Saxons (iron ,in German is Esien ).The atomic symbol for iron is Fe and words like ‘ferrous’ and ‘ferric‘ are derived from the Latin word ferrum, iron.

Iron has long been known and used by man; it appears that it was first smelted by the Hittites in Asia Minor in third millennium BC. Iron is the foundation stone metal of human technology. We use it to construct our society and produce more of it than all metals collectively. The iron era continues today, and in reality the atomic and information ages are only current names to better describe a modern iron-based culture.

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Importance of Iron:

Iron is comprised of 4.6% of earth. The sixth most abundant element in lithosphere. The most abundant metal. Fifth largely used element the other four elements are Hydrogen, Carbon, Oxygen and Calcium. The main factors which affects ranking are annual consumption, natural materials, vital for life, industrial importance, abundance in atmosphere and hydrosphere. Iron is very much important for human body and plants i.e. in haemoglobin, meat and in vegetables.

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