CHEMISTRY HBSC3203

FACULTY OF EDUCATION AND LANGUAGE

JANUARY / 2014

HBSC3203
CHEMISTRY II

MATRICULATION NO:

831230095066001

IDENTITY CARD NO.

831230095066

TELEPHONE NO.

0192878993

E-MAIL

lovesharon863@gmail.com

LEARNING CENTRE

PETALING JAYA

CHEMISTRY HBSC3203

TABLE OF CONTENT
NO.
1.0

TITLE
INTRODUCTION

2.0

PROCESS TO PRODUCE THE STEEL CUTLERY

PAGE NO.
1-2
3-4

STARTING FROM IRON ORE

3.0

TYPES OF POLLUTANTS FROM IRON ORE

INDUSTRY AND ITS EFFECT
3.1
POLLUTANTS THAT CAUSE LAND

5-7

POLLUTION
3.2

POLLUTANTS THAT CAUSE AIR

7-8

POLLUTION
3.3

POLLUTANTS THAT CAUSE LAND AND

9 - 10

WATER POLLUTION
GOVERNMENTS EFFORT TO PREVENT /
4.0

10 - 12

REDUCE THE ENVIRONMENT EFFECTS THAT

OCCUR FROM IRON INDUSTRY.
AS A SCIENCE TEACHER HOW CAN YOU

5.0

12 - 14

EDUCTE YOUR PUPILS IN THE CLASS/SCHOOL

TO PREVENT / REDUCE POLLUTION RELATING
TO IRON INDUSTRY IN THE FUTURE.

6.0

REFERENCE

15 - 16

CHEMISTRY HBSC3203

1.0

INTRODUCTION

Figure 1.0 : A modern steel mill from East Germany city of Eisenhuttenstadt, 1989.
Iron and steel is one of the most fundamental resources needed in industry sectors.
Due to its hardness, durability and very stable in physical structure, iron and steel is
needed in automotive industry, construction and creating tools. Iron is represented with
the symbol Fe (Ferum) with atomic number 26 and is a common element which can be
found beneath Earths surface. The presence of Iron is high in earths outer and inner
core, forming a large percentage of Earth structure.
Iron appears as iron ore beneath Earths crust. Iron ores are rocks and minerals
which can be extracted to produce iron and steel through iron or steel making industry.
There are 4 types of iron ore: magnetitie, hematite, goethite, limonite and siderite.
Magnetite is a type of iron oxides with chemical formula Fe3O4. Due to its magnetic
nature, magnetite could attract small piece of iron. Magnetite has black in color and is
crystalline. Hematite is other type iron oxides with chemical formula Fe2O3. Hematite is
harder than pure iron and appears rhombohedral structure. Goethite has chemical formula
(FeO(OH)) and orthorhombic in shape. Goethite is used as clay earth pigment in oil
painting. Limonite has chemical formula (FeO(OH).n(H2O)) and can be used as pigment
or coloring as it produces yellow ochre. Siderite has chemical formula FeCO3 and can be
found on hydrothermal veins.

CHEMISTRY HBSC3203

Steel differs itself from iron as it contains more carbon than iron has. Steel is
made of iron alloying together with carbon to produce highly resistant product. Carbon is
added to prevent dislocation of iron atoms, strengthening the steel. Steel in the range of
0.002% and 2.1 % carbon content is known as cast iron has better strength and durability
compared to the steel with more than 2.1% of carbon content which is more brittle can
easy to break.
Iron is needed for extensive use in cutlery, automotive engineering, computer
technology and so forth. Therefore, iron or steel making industry plays a vital role to
ensure sufficient supply of iron or steel to various industries. Iron or steel mill is an
industrial plant to produce steel. The mill consists of two stages, the first stage in which
Blast Furnace is needed to smelt the iron with coke and limestone, to produce pig iron.
Pig iron is the intermediate product from blast furnace and has very high in carbon
content (3.5%-4.5%), making it brittle and not useful. The molten pig iron is then put into
Bessemer converter and a stream of pressurized oxygen is then blown along with pig iron
in the converter, burning away impurities in Basic Oxygen Furnace (BOF). In Electric
Arc Furnace (EAF), the molten pig iron is then channeled into the furnace and tap with
refractory brick movable roof. The roof has three large graphite electrodes to transfer
high powered electric shocks onto the surface of the molten iron, making it melt on high
temperature. The molten iron is then mixed with carbon to produce high quality finish
products.
2.0

PROCESS TO PRODUCE THE STEEL CUTLERY STARTING FROM

IRON ORE

CHEMISTRY HBSC3203

Figure 2.1: Manufacturing process for iron and steel.

Figure 2.1 shows process of making iron and steel from iron ore in steel industry.
There are 5 major process of manufacturing steel: iron making, steel making, continuous
casting, rolling and main products.
Iron and steel manufacturing process starts with putting all the raw materials
together into a blast furnace to produce hot metal. The raw materials include iron ore,
pellet, coke, sintered ore, and limestone. The iron ores arrive in different forms: ore
lumps, fine-sized iron ores and pellets. Ore lumps is the size of iron ores which comes
naturally, fine-sized iron ores include iron sand which is fine in size whereas pellets is in
spherical in shape. The temperature of blast furnace is high enough to molt the mixture to
become molten iron. The hot molten iron, at the temperature of 1480C is then poured into
Basic Oxygen Furnace (BOF) or electric arc furnace (EAF) to produce steel. Basic
Oxygen Furnace (BOF) is a type of converter which allows molten pig iron to be
4

CHEMISTRY HBSC3203

converted into steel through oxidation reaction during blowing. A stream of pure oxygen
(>99.9 pure) is introduced on the surface of iron at supersonic speed and blows. Scrap
metals can be introduced into the furnace during the process. The process, is also known
as exothermic process, generates heat and ignites carbon dissolved in the steel to produce
carbon monoxide and carbon dioxide. The presence of the molecules causes increases the
temperature to 1700C to molt the scrap metal and to reduce the carbon content of the
molten iron. Impurities such as silicates and so forth will be eliminated and the molten
iron is then channeled to the steel casting chamber to produce billet, bloom and slab
through Hot Direct Rolling (HDR) process.
In Electric Arc Furnace (EAF) process, the furnace is fed with hot molten iron and
tapped. The tap consists of three large graphite electrodes to provide high power
electrical charges onto the surface of the molten iron. The electrical charge is high
enough (approximately from 1,800C up to 3,000C) to molt the iron, producing molten
steel and thus to eliminate impurities. The molten steel is then channeled to continuous
casting department to produce billet, slab and bloom while it is still hot. The process is
known as Hot Direct Rolling (HDR). The steel will be transported to section mill and
shaped to produce cutlery with different sizes. The cutlery is then packed and transported
for sale.
3.0

TYPES OF POLLUTANTS FROM IRON ORE INDUSTRY AND ITS

EFFECT
There are several types of waste products to be identified which cause serious

pollution in our environment. If the authority neglect the presence of the pollutants in the
area it can poses a threat to our health. Therefore, the authority such as government and
the iron industry management should identify types of pollutants and classify it into types
of pollutions before making a decision to curb or stop the pollutants from spreading
across the affected area.
3.1

POLLUTANTS THAT CAUSE LAND POLLUTION

5

CHEMISTRY HBSC3203

Figure 3.1.1: Slag as waste product.

Slag is the mixture of silica, calcium oxide, magnesium oxide, aluminum and iron
oxides. In other words, slag is the byproduct of steel production. During smelting, the
iron ore is poured into the blast furnace to produce molten iron. The impurities such as
slags and so on are separated from the molten iron and channeled out of the furnace.
Granulating process occurs when the water is poured onto the surface of it, causing slags
to have a bit similar physical and chemical properties of cement. The water is then carries
the slags into the large tank and filtered to produce coarse beach sand like physical look.
The presence of slags causes ph imbalance in the soil which affects microbial activity in
the soil. Microbes such as protozoa, amoeba and organisms such as worm will be
severely affected by slags because it disrupts enzyme activity which requires suitable soil
ph to launch enzymatic activity. The failure of enzymatic activity causes microbes and
small living organisms in the soil to die, severing the infertility of the soil which cannot
be used for farming. (Ediga et al, 2010)

CHEMISTRY HBSC3203

Figure 3.1.2: Physical structure of plumbum lead.

Plumbum lead (Pb) is an air pollutant released from iron foundry during steel
making process. Plumbum is appears in the form of fine particles and is released into the
air during emission, severing the air quality in the area. The airborne, fine particles are
then inhaled by human causing accumulation of plumbum lead in the body. If the blood
lead level is high, the patient is prone to have problems of body processes such as heart,
bones, intestines, kidneys, reproductive and nervous systems.
Adults who suffer plumbum lead poisoning are prone to short-term memory
depression, nausea, abdominal pain, loss of coordination, fatigue, insomnia, headaches,
slurred speech and so on. As for kids, plumbum lead poisoning symptoms include loss of
appetite, constipation, anemia, abdominal pain, kidney failure, irritability, learning
disabilities and behavioral problems. Those who suffer acute plumbum lead poisoning
will cause red blood cells to rupture, leading him or her to suffer anemia and hemoglobin
in the urine.

Figure 3.1.3: Cadmium found

Figure 3.1.4: Cadmium causes Itai-itai

during smelting process.

disease among civilian.

Cadmium is a kind of metal and has low boiling point. Therefore, cadmium
powder is highly flammable and is required in iron making and steel making process to
7

CHEMISTRY HBSC3203

produce molten iron or steel. During iron making or steel making process, fine particles
of cadmium is released from the blast furnace into the air and slowly reacts with oxygen
to produce cadmium oxide. Since cadmium oxide is toxic, it is then inhaled or ingested
by animals or humans into the body causing chronic health risks in the body such as lung
problems, premature death, kidney and liver failure, gastrointestinal tract tissues, joint
pain, nervous, respiratory and reproductive system damage and so forth. Cadmium
poisoning is responsible for causing Itai-itai disease in Toyama Prefecture, Japan in 1912.
Itai-itai disease caused failure in kidneys and softening of bones and thus, causing pains
in the joints and spine (Masanori Kaji, 2012).
3.2

POLLUTANTS THAT CAUSE AIR POLLUTION

Figure 3.2.1 : Dioxin molecule structure.

Dioxin gas is formed during iron making and steel making process. Dioxin is very
toxic to human as it poses harmful effect on organs and systems of human body. Dioxin
gas comes out from blast furnace, Basic Oxygen Furnace and Electric Arc Furnace into
the air during smelting process. The gas is then absorbed by animals and human as it
8

CHEMISTRY HBSC3203

enters into the lungs when breathing. For poultry such as chicken and ducks, dioxin is
then absorbed and accumulated in the food chain, mainly in the animals fatty tissues.
The contaminated poultry is then sold to the consumers and eaten. Since the half life of
dioxin is 7 to 9 years the concentration of dioxin increases as the food chain. This is
because the chemical structure of dioxin is very stable it is stored in the body for a very
long time. The presence of high concentration of dioxin can cause problems in
reproductive system and immune system, interfering hormones. It is also a threat to
humans as it causes cancer.

Figure 3.2.2: Dioxin molecule structure.

Iron and steel making process produces nitrogen oxide. Nitrogen oxide appears
itself in gaseous state, making it hazardous air pollutants. When Nitrogen Oxide is
released into the air, the molecule combines with water to produce acid rain. Since acid
rain has low ph state, it causes damage and rupture of buildings, cars, properties and so
on. The exposure of acid rain on human body can cause irritability of eyes and skins,
nausea, fluid forming in lungs and damages to crops and livestock.
3.3

POLLUTANTS THAT CAUSE LAND AND WATER POLLUTION

CHEMISTRY HBSC3203

Figure 3.3.1: Coke used as fuel in steel mill.

Coke is the carbon product that is formed by the thermal distillation of coal at
high temperatures in the absence of air in coke oven batteries (Donna Lee Jones, 2012).
Coke is used to create carbon monoxide which can reduce iron oxide (hematite) to form
iron in blast furnace. The coke consists of carbonaceous material with high carbon
content and few impurities. The burning of coke in blast furnace releases coke particles
into the air. The air-borne particles pose a threat to organisms if it enters into the body of
organisms through inhalation or water consumption. The particle damages lungs by
hardening alveoli walls, severing gaseous exchange on the membrane of the alveoli walls.
The failure of gaseous exchange causes excessive mucus to be created in the lungs to
facilitate gaseous exchange. Too much mucus can narrows the entry of oxygen in the
lungs, causing someone to suffer asthma. If someone drinks coke-contaminated water, the
presence of the coke in stomach causes problems in digestive system. Coke co-workers in
iron or steel mill are prone to have cancer in the lung, tracheas, bronchus, kidney, prostate
and other parts of their body.

10

CHEMISTRY HBSC3203

Figure 3.3.2 : Naphthalene in physical appearance.

Water is used as cooling agent in coke production. It is also used to separate
product and by-product in the industry. The contaminated water often contains
naphthalene as it is derived from coal tar. As the contaminated water enters our body, it
destroys red blood cells and the availability of the cells decreases over time. Such
reduction can cause patient to suffer hemolytic anemia. Hemolytic anemia can be life
threatening as it causes the breakdown of red blood cells.
4.0

GOVERNMENTS

EFFORT

TO

PREVENT

REDUCE

THE

ENVIRONMENT EFFECTS THAT OCCUR FROM IRON INDUSTRY.

Iron and steel production poses hazardous effects on environment. Therefore,
government intervention is a must to prevent or reduce the pollutants generated during
iron and steel making process.
First of all, The Ministry of Science and Technology should come out with
standards for pollution management and control in iron and steel industry. Industrial
Pollution Control Management (ADB) should monitor and coordinates memorandum
regarding pollution control in iron and steel industry signed by the company and the
government. The ministry should allocate some money to Research and Development
Department to develop new technologies as well as methodologies to control pollution in
iron and steel making process. The government should also bring and introduce latest
11

CHEMISTRY HBSC3203

technologies from oversea to the iron and steel industries. Iron and steel workers should
be exposed with training governed by government authority so that they can be well
adapted with the green technology.
The government must sign Kyoto Protocol to limit the release of harmful gases
into the air. Kyoto Protocol is an international treaty which was introduced by United
Nations Framework Convention on Climate Change (UNFCCC) to the world to regulate
and lessen the release of greenhouse gases into the atmosphere. The treaty also identifies
and recognizes countries with commitment of favoring emission cuts across the world.
Therefore, the government must ensure that iron and steel manufacturer to use all kinds
of technology and methodology to reduce the emission of Carbon Dioxide and Nitrogen
Dioxide in the future. Kyoto Protocol on Climate Change, which was adopted in
December 1997 and later amended at several Conferences of the Parties(COPs)
(Edward Page, 2007).The government should take legal action against the company that
refuses to follow Kyoto Protocol and bring them to court. In association with Clean
Development Mechanism (CDM), the protocol encourages the development of energy
efficient technologies to reduce Carbon Dioxide emission. The equipment is certified and
labeled with Certified Emission Reductions (CERs).
The government should establish Corporate Environmental Responsibility (CER)
in association with Ministry of Environment Malaysia to manage and reduce environment
pollution, solid waste and hazardous waste management. The cooperation with the
government and the CER should be prioritized to come out with measures and
regulations to control the pollution in iron steel industry. The measurements include
minimizing the volume of solid waste, adopting green technologies and in-plant process
control. The CER and the government should also come out with standardization and
implementation of guidelines regarding solid waste pollutants produced by the iron steel
manufacturer. Recycling of steel making slag is an example of solid waste management
to reduce the existence of the waste.

12

CHEMISTRY HBSC3203

The government should working closely with United Nations Development

Program on Global Environment Fund (GEF) to support programs related to energy
efficiency in iron ore industry. The government and UNDP-GEF should grant amount of
money to the company that successfully develop clean technology increase steel
productivity and to reduce the use of electricity which subsequently reduce Carbon
Dioxide emission. The joint partnership between UNDP and Ministry of Steel,
government of India and Global Environment Facility is helping steel sector to save up to
40 percent of energy consumption to reap greater profits.
5.0

AS A SCIENCE TEACHER HOW CAN YOU EDUCTE YOUR PUPILS IN

THE

CLASS/SCHOOL

TO

PREVENT

REDUCE

POLLUTION

RELATING TO IRON INDUSTRY IN THE FUTURE.

Figure 5.1: quiz created using Microsoft PowerPoint.

As a science teacher, I will use multimedia technology in teaching pupils about
the ways to prevent or reduce iron pollution in the future. Therefore, multimedia
equipments such as computer, digital scanner, projectors and so forth are a must to
achieve the goal.
First of all, PowerPoint is needed to enable pupils understand about the ways to
prevent or reduce pollution. PowerPoint is a slide presentation program to give an
audience a glimpse of content knowledge. The PowerPoint must be enclosed with
pictures about types of pollutants and the effect of pollutants to cause pollution in Mother
13

CHEMISTRY HBSC3203

Nature as well as ways to reduce pollution. Every picture related to the topic with a
simple description gives pupils a clear view on how pollutants affect the Mother Nature.
Since PowerPoint has Graphical User Interface features such as animated buttons and
sound effects, it can be used to create simple quiz related to the topic so that pupils are
given a chance to answer the quiz using the computer. The quiz can be created by
creating hyperlinks on correct and incorrect answers. The quiz can be easily answered by
left-clicking the mouse button on the selection to see whether the answer is correct or
incorrect. The PowerPoint has colourful template that it grabs pupils attraction to the
topic.

Figure 5.2 : one of the screen shots from science video.

Secondly, Science teacher should show videos about the reduction of pollutants in
iron or steelmaking industry in front of pupils. The video can be defined as a series of
pictures in correct order to give an audience a clear view while moving visual images.
The video shows about the real live example of iron and steel making process and how
pollutants are released into the air. It also shows about steps to be taken to decrease the
pollutants. Pupils will be able to learn something fast through visual learning therefore
video suits them in teaching and learning process. Video is easy to understand as it
stimulates discussion among pupils.
Group discussion is should be taken place after video and PowerPoint slides are
shown. Pupils are grouped in teams of four or five and are given a piece of mah-jongg
14

CHEMISTRY HBSC3203

paper to write about ways of preventing or reducing pollutants. A representative of each

group is called to present their facts and findings in front of other pupils followed by
corrections, guidance and summarization by the Science teacher. The teacher can show
real and concrete things in front of the pupils. This include recyclable things made of iron
or steel such as empty can food, steel water bottle and other scrap metal. The teacher
should demonstrate on how unwanted scrap metal is managed correctly.
Lastly, the teacher can use Microsoft Word to lists down terms related to the iron
or steel making industry. Each word along with definitions and descriptions are listed in
alphabetical order using table functionality in the application software.

REFERENCES

Anjaneyulu, E., Ramgopal. M., Narasimha, G., Balaji, M. (2010). Effect of Pig Iron Slag
Particles on Soil Microbial and Enzyme Activities. Tirupati: IDOSI Publications.
Stander, G. J., Henzen, M. R., Funke, J. W. (1970). The disposal of polluted effluents
from Mining, Metallurgical and Metal Finishing Industries, their effects on
receiving water and remedial measures. South African Institute: 103: 95-103.
Kanji, M. (2012). Role of Experts and Public Participation in Pollution Control: The
Case of Itai-itai Disease in Japan. Tokyo: Tokyo Institute of Technology
Publication: 111: 99-111.
Viswanathan, P.V., Gangadharan, T.K. (1996). Environmental and Waste Management in
Iron and Steel Industry. Jamshedpur: 207: 199-207.
Page, E. (2007). Analysis Equity and the Kyoto Protocol. Warwick: University of
Warwick.
15

CHEMISTRY HBSC3203

Doushanov, D.L. (n.d.). Control of Pollution in the Iron and Steel Industry. Bulgaria:
University of Bulgaria.
Margolis, N., Brindle, R. (2000). Energy and Environmental Profile of the U.S. Iron and
Steel Industry. United States of America: Energetics
Fierens, S., Mairesse, H., Heilier, J.F., Eppe, J.F.F.G., Pauw, E.D., Bernard, A. (n.s.)
Impacts of Iron and Steel Industry and Waste Incinerators on Human Exposure to
Dioxins, PCBs and Heavy Metals: Results of a Cross-Sectional Study in Belgium.
Liege: University of Liege.
A Manufacturing Process for Iron and Steel. Retrieved February 16, 2014, from
http://www.jfe-21st-cf.or.jp/chapter_2/2a_1.html.
Secondary smelting of nonferrous metals: Impacts, Risks and Regulations. National
Center for Manufacturing Sciences: Environmental Roadmapping Initiative.
Retrieved

from

February

14,

2014,

from

http://www.ecm.ncms.org/ERI/new/IRRsecsmelt.htm.
The

Steel

Making

Industry.

(n.d.).

Retrieved

February

15,

2014,

from

http://www.istc.illinois.edu/info/library_docs/manuals/primmetals/chapter2.htm.
Overview of Steel Making Process. (n.d.). Retrieved February 16, 2014, from
https://www.worldsteel.org/dms/internetDocumentList/bookshop/Steelmakingposter/document/Overview%20of%20the%20steelmaking%20process.pdf.
Iron Ore Processing for the Blast Furnace. (n.d.) Retrieved February 16, 2014, from
http://www.steel.org/~/media/Files/AISI/Making%20Steel/Article
%20Files/ironore.

16

CHEMISTRY HBSC3203

The

Manufacture

of

Steel.

(n.d.)

Retrieved

February

17,

2014,

from

http://nzic.org.nz/ChemProcesses/metals/8A.pdf.
Achieving the Goal of Zero-Waste (2010). Retrieved February 17, 2014, from
http://www.worldsteel.org/dms/internetDocumentList/fact-sheets/Fact-sheet_Byproducts/document/Fact%20sheet_By-products.pdf.
Air Pollution Control in Steel Industry. (2005). Retrieved February 18, 2014, from
http://www.env.go.jp/earth/coop/coop/materials/air_poll/e_steel.pdf
Cadmium General Information. (2010). Retrieved February 18, 2014, from
http://www.hpa.org.uk/webc/hpawebfile/hpaweb_c/1194947386187
Coke

Oven

Emission.

(2000).

Retrieved

February,

2014,

from

http://www.epa.gov/ttn/atw/hlthef/cokeoven.html

17