Coking Factory
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Coking Factory
A coking factory or a coking plant is where Coke (fuel), coke and manufactured gas are synthesized from coal using a dry distillation process. The volatile components of the Pyrolysis, pyrolyzed coal, released by heating to a temperature of between 900Celsius, °C and 1,400 °C, are generally drawn off and recovered. There are also coking plants where the released components are burned: this is known as a heat recovery process. A layer of ash then forms on the surface of the resulting coke. The degassing of the coal gives the coke a highly sought-after porosity. The gases are broken down by fractional condensation into hydrocarbon tars, sulfuric acid, ammonia, naphthalene, Benzoic acid, benzol, and coke gas; these products are then purified in further chemical reactors. Germany still has five coking plants in operation (as of 2010) to meet the needs of its domestic industry. Coke is mainly used to produce cast iron in blast furnaces, which remains its main use today. Degassin ...
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Bituminous Coal
Bituminous coal, or black coal, is a type of coal containing a tar-like substance called bitumen or asphalt. Its coloration can be black or sometimes dark brown; often there are well-defined bands of bright and dull material within the coal seam, seams. It is typically hard but friable. Its quality is Coal analysis#Coal classification by rank, ranked higher than lignite and sub-bituminous coal, but lesser than anthracite. It is the most abundant rank of coal, with deposits found around the world, often in rocks of Carboniferous age. Bituminous coal is formed from sub-bituminous coal that is buried deeply enough to be heated to or higher. Bituminous coal is used primarily for electrical power generation and in the steel industry. Bituminous coal suitable for smelting iron (''coking coal'' or ''metallurgical coal'') must be low in sulfur and phosphorus. It commands a higher price than other grades of bituminous coal (thermal coal) used for heating and power generation. Within the ...
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Flux (metallurgy)
In metallurgy, a flux is a chemical reducing agent, flowing agent, or purifying agent. Fluxes may have more than one function at a time. They are used in both extractive metallurgy and metal joining. Some of the earliest known fluxes were sodium carbonate, potash, charcoal, coke, borax, lime, lead sulfide and certain minerals containing phosphorus. Iron ore was also used as a flux in the smelting of copper. These agents served various functions, the simplest being a reducing agent, which prevented oxides from forming on the surface of the molten metal, while others absorbed impurities into slag, which could be scraped off molten metal. Fluxes are also used in foundries for removing impurities from molten nonferrous metals such as aluminium, or for adding desirable trace elements such as titanium. As reducing agents, fluxes facilitate soldering, brazing, and welding by removing oxidation from the metals to be joined. In some applications molten flux also serves as ...
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Iron Ore
Iron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in color from dark grey, bright yellow, or deep purple to rusty red. The iron is usually found in the form of magnetite (, 72.4% Fe), hematite (, 69.9% Fe), goethite (, 62.9% Fe), limonite (, 55% Fe), or siderite (, 48.2% Fe). Ores containing very high quantities of hematite or magnetite (typically greater than about 60% iron) are known as natural ore or irect shipping ore and can be fed directly into iron-making blast furnaces. 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. In 2011 the ''Financial Times'' quoted Christopher LaFemina, mining analyst at Barclays Capital, saying that iron ore is "more integral to the global economy than any other commodity, except perhaps oil". Sources Elemental iron is virtually absent o ...
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Foundry
A foundry is a factory that produces metal castings. Metals are cast into shapes by melting them into a liquid, pouring the metal into a mold, and removing the mold material after the metal has solidified as it cools. The most common metals processed are aluminum and cast iron. However, other metals, such as bronze, brass, steel, magnesium, and zinc, are also used to produce castings in foundries. In this process, parts of desired shapes and sizes can be formed. Foundries are one of the largest contributors to the manufacturing recycling movement, melting and recasting millions of tons of scrap metal every year to create new durable goods. Moreover, many foundries use sand in their molding process. These foundries often use, recondition, and reuse sand, which is another form of recycling. Process In metalworking, casting involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified pa ...
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Friability
In materials science, friability ( ), the condition of being friable, describes the tendency of a solid substance to break into smaller pieces under stress or contact, especially by rubbing. The opposite of friable is indurate. Substances that are designated hazardous, such as asbestos or crystalline silica, are often said to be friable if small particles are easily dislodged and become airborne, and hence respirable (able to enter human lungs), thereby posing a health hazard. Tougher substances, such as concrete, may also be mechanically ground down and reduced to finely divided mineral dust. However, such substances are not generally considered friable because of the degree of difficulty involved in breaking the substance's chemical bonds through mechanical means. Some substances, such as polyurethane foams, show an increase in friability with exposure to ultraviolet radiation, as in sunlight. Friable is sometimes used metaphorically to describe "brittle" personalities wh ...
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Hardness
In materials science, hardness (antonym: softness) is a measure of the resistance to plastic deformation, such as an indentation (over an area) or a scratch (linear), induced mechanically either by Pressing (metalworking), pressing or abrasion (mechanical), abrasion. In general, different materials differ in their hardness; for example hard metals such as titanium and beryllium are harder than soft metals such as sodium and metallic tin, or wood and common plastics. Macroscopic hardness is generally characterized by strong intermolecular bonds, but the behavior of solid materials under force is complex; therefore, hardness can be measured in different ways, such as scratch hardness, indentation hardness, and rebound hardness. Hardness is dependent on ductility, elasticity (physics), elastic stiffness, plasticity (physics), plasticity, deformation (mechanics), strain, strength of materials, strength, toughness, viscoelasticity, and viscosity. Common examples of hard matter are cer ...
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Water Content
Water content or moisture content is the quantity of water contained in a material, such as soil (called ''soil moisture''), rock, ceramics, crops, or wood. Water content is used in a wide range of scientific and technical areas, and is expressed as a ratio, which can range from 0 (completely dry) to the value of the materials' porosity at saturation. It can be given on a volumetric or mass (gravimetric) basis. Definitions Volumetric water content, θ, is defined mathematically as: :\theta = \frac where V_w is the volume of water and V_\text = V_s + V_w + V_a is equal to the total volume of the wet material, i.e. of the sum of the volume of solid host material (e.g., soil particles, vegetation tissue) V_s, of water V_w, and of air V_a. Gravimetric water content is expressed by mass (weight) as follows: :u = \frac where m_w is the mass of water and m_s is the mass of the solids. For materials that change in volume with water content, such as coal, the gravimetric water content, ...
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Carbon
Carbon () is a chemical element; it has chemical symbol, symbol C and atomic number 6. It is nonmetallic and tetravalence, tetravalent—meaning that its atoms are able to form up to four covalent bonds due to its valence shell exhibiting 4 electrons. It belongs to group 14 of the periodic table. Carbon makes up about 0.025 percent of Earth's crust. Three Isotopes of carbon, isotopes occur naturally, carbon-12, C and carbon-13, C being stable, while carbon-14, C is a radionuclide, decaying with a half-life of 5,700 years. Carbon is one of the timeline of chemical element discoveries#Pre-modern and early modern discoveries, few elements known since antiquity. Carbon is the 15th abundance of elements in Earth's crust, most abundant element in the Earth's crust, and the abundance of the chemical elements, fourth most abundant element in the universe by mass after hydrogen, helium, and oxygen. Carbon's abundance, its unique diversity of organic compounds, and its unusual abi ...
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Cast Iron
Cast iron is a class of iron–carbon alloys with a carbon content of more than 2% and silicon content around 1–3%. Its usefulness derives from its relatively low melting temperature. The alloying elements determine the form in which its carbon appears: Cast iron#White cast iron, white cast iron has its carbon combined into an iron carbide named cementite, which is very hard, but brittle, as it allows cracks to pass straight through; Grey iron, grey cast iron has graphite flakes which deflect a passing crack and initiate countless new cracks as the material breaks, and Ductile iron, ductile cast iron has spherical graphite "nodules" which stop the crack from further progressing. Carbon (C), ranging from 1.8 to 4 wt%, and silicon (Si), 1–3 wt%, are the main alloying elements of cast iron. Iron alloys with lower carbon content are known as steel. Cast iron tends to be brittle, except for malleable iron, malleable cast irons. With its relatively low melting point, g ...
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Fuel
A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work (physics), work. The concept was originally applied solely to those materials capable of releasing chemical energy but has since also been applied to other sources of heat energy, such as Nuclear power, nuclear energy (via nuclear fission and nuclear fusion). The heat energy released by reactions of fuels can be converted into mechanical energy via a heat engine. Other times, the heat itself is valued for warmth, cooking, or industrial processes, as well as the illumination that accompanies combustion. Fuels are also used in the Cell (biology), cells of organisms in a process known as cellular respiration, where organic molecules are oxidized to release usable energy. Hydrocarbons and related organic molecules are by far the most common source of fuel used by humans, but other substances, including radioactive metals, are also utilized. Fu ...
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