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When the metal had cooled and hardened, the smaller ingots (the "pigs") were simply broken from the runner (the "sow"), hence the name "pig iron". [4] As pig iron is intended for remelting, the uneven size of the ingots and the inclusion of small amounts of sand are insignificant issues when compared to the ease of casting and handling.
Smelting involves more than just melting the metal out of its ore. Most ores are the chemical compound of the metal and other elements, such as oxygen (as an oxide), sulfur (as a sulfide), or carbon and oxygen together (as a carbonate). To extract the metal, workers must make these compounds undergo a chemical reaction.
In nature, iron, copper, lead, nickel, and other metals are found in impure states called ores, often oxidized and mixed in with silicates of other metals. During smelting, when the ore is exposed to high temperatures, these impurities are separated from the molten metal and can be removed. Slag is the collection of compounds that are removed.
The end products are usually molten metal and slag phases tapped from the bottom, and waste gases exiting from the top of the furnace. [2] The downward flow of the ore along with the flux in contact with an upflow of hot, carbon monoxide-rich combustion gases is a countercurrent exchange and chemical reaction process. [3]
The Chernobyl corium is composed of the reactor uranium dioxide fuel, its zircaloy cladding, molten concrete, as well as other materials in and below the reactor, and decomposed and molten serpentinite packed around the reactor as its thermal insulation. Analysis has shown that the corium was heated to at most 2,255 °C (4,091 °F), and ...
Casting – molten metal is poured into a shaped mold. Variants of casting include sand casting, investment casting, also called the lost wax process, die casting, centrifugal casting, both vertical and horizontal, and continuous castings. Each of these forms has advantages for certain metals and applications considering factors like magnetism ...
Aluminium dross. Dross is a mass of solid impurities floating on a molten metal or dispersed in the metal, such as in wrought iron. It forms on the surface of low-melting-point metals such as tin, lead, zinc or aluminium or alloys by oxidation of the metal.
Near the bottom, one or more pipes (made of clay or metal) enter through the side walls. These pipes, called tuyeres, allow air to enter the furnace, either by natural draught or forced with bellows or a trompe. An opening at the bottom of the bloomery may be used to remove the bloom, or the bloomery can be tipped over and the bloom removed ...