Extraction of Iron Ore

Iron is the fourth-most common element in Earth's crust, and the second-most
common metal after aluminium. It is about 21% of total metal of Earth’s crust and 6.2% of
total elements. It belongs to transition group of the periodic table. Its electronic configuration
is 2,8,8,6,2. The element is found commonly in the Sun, asteroids, and stars.

The chemical symbol for iron, Fe, comes from the Latin name for the element, ferrum. The
most common ores of iron are hematite and limonite.

Three processes involved in the extraction of Iron ore, which are explained
below: -

1. Concentration of ore: - First of all ore is crushed into minute particles

and the crushed ore is concentrated by gravity separation method..

2. Calcination :-Concentrated ore is calcinated in a furnace. During

calcinations moisture is removed. Impurities like Sulphur Changes into
sulphur dioxide and Arsenic into arsenic oxide, phosphorus to phosphorous
oxide, all escape out in the form of gases.

Fe2O3.3H2O Fe2O3 + 3H20

2FeCO3 2FeO + 2CO2

4Fe + 3O2 2Fe2O3

It is due to the presence of some ferrous carbonate that iron changes

into oxide. Ferrous carbonate which is present in some quantity in
hematite not only oxidizes all other impurities into its oxides but also
oxidized itself into iron oxide.

3. Smelting :-Iron oxide is reduced with carbon. Process of smelting is

done in blast furnace which is shown in figure.

Calcinated iron oxide is added in blast furnace along with coke. Coke
serves as fuel as well as reducing agent. Lime is also added in the blast furnace
which serves as flux. The following reactions take place in the furnance:

FIGURE FOR THE BLAST FURNACE

1
(a) At the base of the furnace: Coke reacts with oxygen to produce Carbon
dioxide which moves up and lot of heat is produced.

C + O2 CO2
Coke Oxygen Carbon dioxide

As the carbon dioxide moves upward it is brought in contact with coke and gets
converted into carbon monoxide.

C02 + C 2CO
Carbon Dioxide Coke 1475-1575K Carbon Monoxide

(b) In the middle of the furnace :- In the middle of the furnace

temperature is 1075 to 1275 k. In this region calcium carbonate decomposes to
produce calcium oxide and carbon dioxide. Calcium oxide so produced combines
with silica to form slag.

CaCO3 CaO + CO2

Calcium Carbonate 1075-1275 K Calcium oxide Carbon
Dioxide

CaO + SiO2 CaSiO3

Calcium Oxide Silica Calcium Silicate (Slag)

2
(c) At the top portion of the furnace :- In the top portion of furnace the
Iron(III) oxide react with carbon monoxide to give liquid iron which moves
towards the button of furnace and settled there. This iron is called cast
iron.

Fe2O3 + 3CO Fe + CO2

Ferric oxide Carbon Monoxide Iron Carbon dioxide