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Describe the process of iron extraction in a blast furnace, including the role of limestone and the reactions involved.

Chemistry

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Part a(i)

One of the substances in the slag

Calcium silicate (CaSiO3\text{CaSiO}_3)

Part a(ii)

Another iron ore material used in the blast furnace

Magnetite (Fe3O4\text{Fe}_3\text{O}_4)

Part a(iii)

One gas which is recycled

Carbon monoxide (CO\text{CO})

Part b· 3 steps

Describe the process which leads to the formation of iron in the blast furnace

  1. Coke reacts with hot air to form carbon dioxide.

    C(s)+O2(g)→CO2(g)\text{C}(s) + \text{O}_2(g) \to \text{CO}_2(g)

  2. Carbon dioxide reacts with more hot coke to form carbon monoxide, which is the main reducing agent.

    CO2(g)+C(s)→2CO(g)\text{CO}_2(g) + \text{C}(s) \to 2\text{CO}(g)

  3. Carbon monoxide reduces the iron ore (haematite) to molten iron in stages.

    3CO(g)+Fe2O3(s)→2Fe(l)+3CO2(g)3\text{CO}(g) + \text{Fe}_2\text{O}_3(s) \to 2\text{Fe}(l) + 3\text{CO}_2(g)

    At higher temperatures, coke can also directly reduce the iron oxide.

    3C(s)+Fe2O3(s)→2Fe(l)+3CO(g)3\text{C}(s) + \text{Fe}_2\text{O}_3(s) \to 2\text{Fe}(l) + 3\text{CO}(g)

Part c

State the purpose of limestone in the blast furnace

Limestone (CaCO3\text{CaCO}_3) decomposes to form calcium oxide (CaO\text{CaO}), which acts as a flux. It reacts with acidic impurities like silicon dioxide (SiO2\text{SiO}_2) to form molten slag (calcium silicate, CaSiO3\text{CaSiO}_3), which can be easily removed.

CaCO3(s)→CaO(s)+CO2(g)\text{CaCO}_3(s) \to \text{CaO}(s) + \text{CO}_2(g) CaO(s)+SiO2(s)→CaSiO3(l)\text{CaO}(s) + \text{SiO}_2(s) \to \text{CaSiO}_3(l)

Part d

Give a reason why the melting point of iron obtained from the blast furnace is 1200∘C1200^\circ\text{C} while that of pure iron is 1535∘C1535^\circ\text{C}

The iron obtained from the blast furnace (pig iron) contains impurities, mainly carbon (about 4%), which lower its melting point. Pure iron has a higher melting point because it lacks these impurities.

Part e

State two uses of steel

  • Construction: Used in making beams, reinforcing bars, and structural frameworks for buildings and bridges.
  • Manufacturing: Used in making car bodies, machinery, tools, and household appliances.
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