INSTITUTE OF SPACE TECHOLOGY ISLAMBAD

Extraction of Material
Material Science and Engineering Department
Assignment no:01

SUBMITTED TO
Sir Abdul Qadir
SUBMITTED BY
Muhammad Shaheer
REG NO. 230301017
MAT 16
 Iron ore

Iron ore is a critical raw material for steel production, and its geological occurrence
and distribution are vital for understanding global supply dynamics. Here is a
detailed overview of iron ore's geological occurrence and distribution:

Geological Occurrence
Types of Iron Ore:
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Iron ore is a critical raw material for steel production, and its geological occurrence and
distribution are vital for understanding global supply dynamics. Here is a detailed overview of
iron ore's geological occurrence and distribution:

Geological Occurrence

1. Types of Iron Ore:

o Magnetite (Fe3O4): Contains 72.4% iron. It is magnetic and usually found in
large, well-consolidated deposits.
o Hematite (Fe2O3): Contains 69.9% iron. It is the most abundant form of iron ore
and has a reddish appearance.
o Goethite (FeO(OH)): Contains 62.9% iron. It is formed from the weathering of
other iron-rich minerals.
o Limonite (FeO(OH)·nH2O): Contains approximately 55% iron. It is a mixture
of hydrated iron oxide minerals.
o Siderite (FeCO3): Contains 48.2% iron. It often occurs in sedimentary rocks.
2. Formation:
o Banded Iron Formations (BIFs): The primary source of iron ore, BIFs are
sedimentary rocks consisting of alternating layers of iron-rich minerals and silica
(chert). These formations date back to the Precambrian era (2.5 to 1.8 billion
years ago) and are typically found in ancient cratons.
o Magmatic Deposits: Iron ore can also form from magmatic processes where iron-
rich magma cools and crystallizes, leading to the formation of magnetite deposits.
o Lateritic Deposits: Formed by intensive weathering of iron-rich rocks in tropical
climates, concentrating iron oxides near the surface.
o Metamorphic Deposits: Metamorphism of iron-rich sediments can lead to the
formation of hematite and magnetite through recrystallization processes.

3. Distribution
 1. Global Reserves and Production:
o Australia: The largest producer, with vast reserves in the Pilbara region. Key mines
include the Hamersley Basin and the Karara Mine.
o Brazil: Rich in high-grade hematite ores, with significant deposits in the Carajás and
Quadrilátero Ferrífero regions.
o China: Extensive reserves but often of lower grade. Key mining regions include the
Anshan-Benxi area.
o India: Significant deposits found in Odisha, Jharkhand, and Chhattisgarh. The Bailadila
range is notable for high-grade hematite ore.
o Russia: Large deposits in the Kursk Magnetic Anomaly and the Kola Peninsula.
o South Africa: Major reserves in the Transvaal Basin, including the Sishen and
Thabazimbi mines.
o United States: Principal deposits in the Lake Superior region, including the Mesabi
Range.

2. Economic Factors:
o Market Demand: Driven primarily by the steel industry, with China being the largest
consumer.
o Technological Advancements: Improvements in mining and beneficiation technologies
have made it possible to exploit lower-grade ores economically.
o Environmental Regulations: Stricter regulations in some countries can affect mining
operations and exploration activities.

3. Strategic Importance:
o Supply Chain: Dependence on iron ore imports can affect national security and
economic stability.
o Price Volatility: Prices can fluctuate significantly based on global demand, geopolitical
events, and changes in production levels.

Primary methods used for extraction

Iron ore extraction involves several key methods, each tailored to the specific characteristics of
the ore deposit. The primary methods used for iron ore extraction include surface mining,
underground mining, and the beneficiation process. Here’s an in-depth look at each method:

1. Surface Mining

Surface mining is the most common method for iron ore extraction. It is economical when ore
deposits are located close to the Earth's surface. Key techniques include:

a. Open-Pit Mining

 Process: Involves removing large quantities of overburden (soil and rock overlaying the
ore) to access the ore body.
 Equipment: Heavy machinery such as excavators, draglines, and trucks.
 Advantage: High ore recovery and efficient for large, shallow deposits.
 Example: Pilbara region in Western Australia.
b. Strip Mining

 Process: Similar to open-pit mining but used for horizontal ore bodies.
 Technique: Sequential removal of strips of overburden and ore.
 Advantage: Cost-effective for deposits with a flat-lying orientation.

2. Underground Mining

Underground mining is employed when ore bodies are deep below the surface. It involves
creating tunnels or shafts to access the ore. Key techniques include:

a. Room and Pillar Mining

 Process: Involves mining rooms of ore while leaving pillars of unmined material to
support the roof.
 Application: Suitable for horizontal or gently dipping ore bodies.
 Advantage: Safer and more controlled environment compared to open-pit mining.

b. Sublevel Caving

 Process: Ore is broken from the roof or back of an underground level, and broken ore is
collected at the bottom.
 Technique: Involves blasting and allowing the ore to cave in naturally.
 Advantage: Efficient for large ore bodies with steep dips.

c. Block Caving

 Process: Similar to sublevel caving but on a larger scale. Entire ore blocks are undercut,
causing them to break and cave in under their own weight.
 Advantage: Cost-effective for very large and deep deposits.

3. Beneficiation Process

Once the ore is extracted, it undergoes beneficiation to increase the iron content and remove
impurities. Major processes include:

a. Crushing and Grinding

 Process: Ore is crushed and ground to liberate the iron minerals from the gangue (waste
material).
 Equipment: Crushers, mills, and grinding equipment.
 Result: Produces fine particles for further processing.
b. Magnetic Separation

 Process: Utilizes the magnetic properties of magnetite to separate it from non-magnetic

waste.
 Technique: Magnetic separators are used to concentrate magnetite ores.
 Advantage: Efficient for magnetite ores.

Chemical and physical processes involved in extraction

1. Crushing and Grinding

 Physical Process: The ore is crushed into smaller pieces and then ground into fine
particles to liberate iron minerals from the waste rock.
 Equipment: Crushers and grinding mills.
 Result: Produces fine ore particles suitable for further processing.

1. Blast Furnace Smelting

 Chemical Process: The primary method for producing iron from iron ore, involving
several key steps:
o Charging: The blast furnace is charged with a mixture of iron ore, coke (carbon
source), and limestone (flux).
o Combustion: Hot air is blown into the furnace, causing the coke to combust and
generate heat.
o Reduction: The generated carbon monoxide reacts with iron ore (primarily
hematite and magnetite) to reduce it to metallic iron.
 Fe2O3 + 3CO → 2Fe + 3CO2
 Fe3O4 + 4CO → 3Fe + 4CO2

Environmental impact associated with extraction

Iron ore extraction, while essential for industrial development, has significant environmental
impacts. These impacts arise from the mining operations, beneficiation processes, and
transportation of iron ore. Here's a comprehensive overview of the environmental effects
associated with iron ore extraction:

Key impacts:
1. Land Degradation
2. Water Pollution
3. Air Pollution
4. Noise and Vibration
5. Energy Consumption
Economic significance and industrial application
Aspect Details
Global Market and
Trade
Leading Producers Australia, Brazil, China, India
Exporters Australia, Brazil
Importers China (largest), other industrialized countries
Economic Impact
Revenue Generation Significant revenue from exports, taxes, royalties
Employment Millions employed worldwide in extraction, processing,
transportation
Infrastructure Mining revenues fund infrastructure projects (roads,
Development railways, ports)
Price Volatility
Market Dynamics Influenced by supply and demand, geopolitical factors,
economic conditions
Industrial Impact Affects profitability of mining companies, cost structure of
steel producers
Steel Production
Primary Use Main raw material for steel production
Process Iron ore converted to pig iron in blast furnace, refined to
steel
Forms of Steel Structural steel, stainless steel, specialty steels
Construction Industry
Structural Components Buildings, bridges, infrastructure
Reinforcement Steel-reinforced concrete structures
Automotive Industry
Vehicle Manufacturing Steel for vehicle frames, bodies
Safety Features Advanced high-strength steels in airbags, seat belts, crash-
resistant structures
Machinery and
Equipment
Industrial Machinery Mining machinery, agricultural tools
Engineering Precision components like gears, shafts, bearings
Applications
Energy Sector
Pipelines Construction of oil, natural gas pipelines
Energy Infrastructure Power plants, wind turbines
Household Appliances
Durable Goods Manufacturing of refrigerators, washing machines, ovens
Consumer Products Kitchen utensils, furniture
Transportation
Railways Steel rails, tracks, railway components
Shipbuilding Hulls and structures of ships
Innovation and Future
Trends
Sustainable Production Recycling scrap steel, green technologies like hydrogen-
based reduction, electric arc furnaces
High-Performance Advanced high-strength steels (AHSS), nanostructured steel
Materials for improved properties
Automation and Smart mining, Industry 4.0 in steel production, improving
Digitalization efficiency, safety, sustainability