cast and pig iron flow diagram

Here’s a simplified flow diagram for the production of cast iron and pig iron, highlighting key steps from raw materials to final products:

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Pig Iron & Cast Iron Production Flow Diagram

1. Raw Materials Preparation
– Iron ore (e.g., hematite, magnetite)
– Coke (carbon source)
– Limestone (flux to remove impurities)
– Scrap steel/recycled iron (optional)

2. Blast Furnace (Pig Iron Production)
– Raw materials are charged into the furnace.
– Hot air (1200°C) is blasted into the furnace to facilitate reactions:
– Coke burns: \( \text{C} + \text{O}_2 → \text{CO}_2 \)
– CO reduces iron ore: \( \text{Fe}_2\text{O}_3 + 3\text{CO} → 2\text{Fe} + 3\text{CO}_2 \)
– Limestone reacts with impurities (slag formation).
– Molten pig iron (~4% carbon) collects at the bottom and is tapped.

3. Pig Iron Refining
– Pig iron is either:
– Cast into ingots for further processing (e.g., steelmaking).
OR
– Converted to cast iron in a cupola furnace or electric arc furnace.

4. Cast Iron Production
– Pig iron is remelted with scrap iron/steel and alloying elements (Si, Mn).
– Carbon content adjusted (~2–4%).
– Molten cast iron is poured into molds for casting.

5. Final Products
– Pig Iron: Used as feedstock for steelmaking or sold as-is.
– Cast Iron: Engine blocks, pipes, cookware, etc.

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Simplified Flowchart
“`
Iron Ore + Coke + Limestone
↓
Blast Furnace
↓
Molten Pig Iron
/ \
Steelmaking Cast Iron Production
↓
Casting/Molding
↓
Cast Iron Products
“`

Key Notes:
– Pig Iron: High-carbon (~4% C), brittle, used primarily for steel production.
– Cast Iron: Lower carbon (~2–4%), silicon-rich, better