IRON AND STEEL INDUSTRYCourtesy: Class X,

2007

PROJECT LAYOUTRAW MATERIALS

PROCESSES

OUTPUT[PRODUCTS]

USES OF PRODUCTS

LOCATION

IMPORTANCE OF LOCATION

PROBLEMS

Faced by Industry

Faced by people, environment and economy.

QUESTION BANK [2000-2007]

• Steel is a metal composed of iron plus varying amounts of carbon as well as other elements such as chromium, nickel, molybdenum, zirconium, vanadium, tungsten.

• Different types of steel are produced by adjusting the chemical composition and adapting any of the different stages of the steelmaking process, such as rolling, finishing and heat treatment.

WHAT IS STEEL AND IRON?

•Iron is a lustrous, silvery soft metal. It is extracted from iron ore, and is almost never found in the free elemental state. In order to obtain elemental iron, the impurities must be removed by chemical reduction.

• Iron is the main component of steel, and it is used in the production of alloys or solid solutions of various metals, as well as some non-metals, particularly carbon.

RAW MATERIALS

1. IRON ORE

Iron ores are rocks and minerals from which metallic iron can be economically extracted. Iron ore is the raw material used

To make pig iron, which is one of the main raw materials

to make steel. 98% of the mined iron ore is used to make steel.

2. MANGANESE

It is found as the free element in nature (often in combination with iron), and in many minerals. The free element is a metal with important industrial metal alloy uses. Manganese is essential to iron and steel production by virtue of its sulfur-fixing, deoxidizing, and alloying properties.

3. COKING COAL

Coke is a solid carbonaceous material derived from destructive distillation of low-ash, low-sulfur bituminous coal. The volatile constituents of the coal—including water, coal-gas, and coal-tar—are driven off by baking in an airless oven at temperatures as high as 2,000 degrees Celsius. This fuses together the fixed carbon and residual ash. Most coke in modern facilities is produced in "by-product" coke ovens, and the resultant coke is used as the main fuel in iron-making blast furnaces.

4) LIMESTONELimestone is a sedimentary rock composed largely of the mineral calcite (calcium carbonate: CaCO3).

5) WATERLarge quantities of water are required in the steel making process.

PROCESSES

STEEL MAKINGHeating in coke ovens = Volatile components of bituminous coal removed. Coke remains as partially graphitized solid residue.

Ore, coke and stone introduced regularly in the blast furnace. These are heated by rising hot gases.

Carbon monoxide react with iron oxides = Form metallic iron and carbon dioxide. The iron melts and dissolves carbon as it percolates through the coke column.

By the time it reaches the hearth, it is saturated with carbon and contains silicon, phosphorus manganese and sulphur. The stone and ore form a low-melting, free-running liquid slag, which absorbs most of the sulphur entering the furnace (coke is the main sulphur source).

Liquid slag, composed of gangue minerals and oxide components of stone, floats on the liquid iron and is separated from the molten metal during furnace tapping. The coke does not melt; it burns on contact with the pressured, preheated air ("blast") entering through the tuyères located just above the hearth.

OUTPUTS and USES

1) Steel billets Manufacturing plain, deformed, twisted and ribbed bars. Steel sections: rails, angles, joints, channels, squares, flat bars, rods, wire rods, bailing hoops, tees and chains etc. seamless pipes. machine components. Forging and stamping. spring steel flat bars.

Billets are used to make different bars…which are used in making railways, machine parts and chains etc.

2) Hot Rolled ProductsSeam Welded Pipes for Gas/Water/Oil.Storage Tanks, Vessels, Containers.Ships/Barges, Launches & Floating Structures.Fabricated Sections/Structures.General Purpose Sheets/Plates.Wheel Rims. Formed Sections, Steel Flooring and Cold Rolled Products.

Hot rolled carbon steel coils are used for welded pipes, wheel rims and ships etc.

3) Cold Rolled Sheets/Coils.

4) Galvanized ProductsAutomobiles, Roofing, Shuttering, Panelling, Manufacture of buckets, utensils, cans, containers Desert coolers, Air conditioners, Water coolers, Fresh water tanks, etc, Domestic appliances.Galvanized steel is used for automobiles, air-conditioners, water tanks etc.

5) Coke•Widely used as a fuel by foundries in cupolas for melting iron scrap and pig iron.•In sugar mills employing the carbonizing process.•For making chemicals/calcium carbide.•Used in the pharmaceutical industries.•Coke breeze is used for steam generation in boiler houses.•Used in Steel making for carbon adjustment.•Coke fuel is used in sugar mills, pharmaceutical companies and in generators.

7) Pig Iron

BY PRODUCTS

Ammonium Sulphate

Coal tar Granulated slag

Boulder slag

BY PRODUCTS

• Oxygen & Nitrogen

• Coal Tar

• Granulated Blast Furnace Slag

• Refractory Bricks

• Boulder Slag

• Ammonium Sulphate

TAXILA

GUJRAT

WAZIRABAD

GUJRANWALA

FAISALABAD

LAHORE

KARACHI

HYDERABAD

PAKISTAN STEEL MILLS

…PAKISTAN STEEL is located at a distance of 40 km South East of Karachi at Bin Qasim in close vicinity of Port Muhammad Bin Qasim at Pipri.

It is spread over an area of 18,660 acres (about 29 square miles) including 10,390 acres for the main plant, 8070 acres for township and 200 acres for 110 MG water reservoir. In addition it has leasehold rights over an area of 7520 acres for the quarries of limestone and dolomite in Makli and Jhimpir areas of district Thatta.

FACTORS AFFECTING LOCATION

SITE: Flat, cheap and unused land available.

NATURAL ROUTES: Port Qasim facilitates exports and imports.

CAPITAL:USSR provided economic assistance (technology and capital)

RAW MATERIALS: Iron ore and manganese imported through Port Qasim. Limestone from Makli Hills near Thatta. Water from Lake Haleji nearby.

ENERGY: Port Qasim and Karachi have the highest electricity generating capacity in Pakistan.

LABOUR: Available locally from Karachi.

MARKETS: Most industries are located in Karachi. Over half of the steel produced is used in Punjab.

TRANSPORT: Pipri is connected to main Karachi-Kotri railway. Metalled road also connect this area to the main road network.

PICTURES OF PAKISTAN STEEL MILLS

IMPORTANCE OF THE I & S INDUSTRY

• ATTRACTIVE MARKET DYNAMICS• Captive Market• Growing Market• COMPETITIVE POSITIONING• LONG TERM RAW MATERIAL

CONTRACTS• IDEAL LOCATION• IMPROVED FINANCIALS• EXPANSION POSSIBILITY• ENVIRONMENT, HEALTH & SAFETY

CERTIFICATION• EXPERIENCED MANAGEMENT AND

WORKFORCE

PSMC with a installed capacity of 1.1 million tonnes per annum (“mtpa”), is the country’s only integrated steel manufacturer, accounting for approximately 23% of the country’s total demand for steel in 2004.

DID YOU KNOW?

EFFECTS ON THE ENVORIMENT

• Pollution is caused by the ships coming to supply raw materials.

• Natural reserves of coal, gas are being exploited for the raw material and power supply.

• Fresh water is used in the industry.

PROBLEMS OF THE I & S INDUSTRY

Environmental problemsA lot of pollution is caused by the iron and steel industries. When the iron ore is burned at high temperatures to be melted a lot of smoke is released which in turn goes out into the environment causing a lot of harm to it. This also causes ozone depletion which in turn leads to global warming.

Economic Problems:Since Pakistan is not very abundant in iron ore it has to import a lot of iron ore in order to manufacture steel here. This causes the spending of foreign exchange. Also a lot of iron and steel is needed in day to day life since most of the things are made with this raw material which could lead to the exhaustion of resources.

Social ProblemsWorkers live and work under very poor conditions. We see the basic violation of human rights when the workers are made to work in extremely high temperatures from day to night. Also they accommodation facilities are not that good. People do not lead quality lives. The wages are also quite low considering the amount of work they workers do.

QUESTION BANKAdapted from: O LEVEL 2059/2 PAST PAPERS 2000-

2007JUNE 2006/PAPER II/QS.4

FROM OTHER COUNTRIES

FROM PAKISTAN

PAKISTAN STEEL

COKING COAL

W

Y Z

X

COKING COAL

a) Study Fig. 5, a diagram showing some inputs to Pakistan Steel.

i) Name the two raw materials W and X.

ii) Name two other inputs Y and Z.

iii) Why is coal imported in addition to that produced in Pakistan?

[2]

[2]

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Fig. 5

b) Describe how two human inputs contribute to production at Pakistan Steel?

c) Why is over 50% of the output of Pakistan Steel sent north from Karachi to Punjab?

d) What features of Pakistan Steel show that it is an industry in the formal sector?

e) How does the government attract local and foreign investors to develop industries in Pakistan?

[6]

[3]

[4]

[6]

November 2005/Paper II/Qs. 4

c)

i) Give a location in Pakistan for

A the iron and steel industry

B the cement industry

ii) Choose one of these industries, and state two inputs and two outputs of that industry.

[2]

[4]

***THE END***

PAST PAPER QUESTION FROM 2000-07

QUESTION 4:(a) Study the diagram below showing some inputs to

Pakistan Steel.

i. Name the two raw materials w and x.ii. Name two inputs y and z.iii. Why is coal imported in addition to that is

produced in Pakistan?(b) Describe how two human inputs contribute to

production at Pakistan steel?(c) Why is over 50% of the output of Pakistan steel

sent to north from Karachi to Punjab?(d) What features of Pakistan steel show that it is an

industry in the formal sector?(e) How does the government attract the local and

foreign investors to develop industries in Pakistan? (June 2006)

i. Name the two raw materials w and x.ii. Name two inputs y and z.iii. Why is coal imported in addition to that is

produced in Pakistan?(b) Describe how two human inputs contribute to

production at Pakistan steel?(c) Why is over 50% of the output of Pakistan steel

sent to north from Karachi to Punjab?(d) What features of Pakistan steel show that it is an

industry in the formal sector?(e) How does the government attract the local and

foreign investors to develop industries in Pakistan? (June 2006)