§ 8. Ferrous metallurgy

Ferrous metallurgy is heavy industry branch which the enterprises for extraction and enrichment of ore and nonmetallic raw materials for ferrous metallurgy, on manufacture of refractory materials, products of the coke chemical industries, on melt of cast-iron, a steel, hire and reception of ferroalloys, pipes steel and cast-iron, products of the further repartition (rail fastenings, the white tin, zinced iron), extraction of iron­. The basic ­ raw material for ferrous metallurgy is iron ore.

Enrichment of minerals is a set of processes of primary processing of mineral raw materials.

The crushed ore is enriched with the method with flotations (emerging) with which help there is a division of ore into tails and concentrates­.

Combination of ore of nonferrous metals is usually complex raw materials which can serve as an initial material for reception not only one, but more often variety of metals and, except that, other elements. Integrated approach of raw materials creates conditions and necessarily demands ­ its combined use for the purpose of the maximum extraction ­ of valuable metals containing in ore.

Metallurgy covers all process of manufacture of metals: extraction ­ and preparation of ores, fuel, metal release, manufacture of auxiliary ­ materials (refractory materials, oxygen and etc.). Therefore in metallurgical manufacture of Kazakhstan the ­ manufacture combination is widely developed­.

Ferrous metals are the industrial name of iron and its alloys ­(cast-iron, a steel, ferroalloys, etc.). The structure of alloys except carbon includes also other elements: silicon, manganese, phosphorus, sulphur. Ferrous metals differ with the maintenance in them of carbon. So, if in iron-carbon alloy the maintenance of carbon does not exceed 2 %, it is called steel and if as a part of an alloy there are 2-6 % of carbon, is a cast-iron. Cast-iron melt from iron ore in blast furnaces, steel is melted in martin, converter, electric furnaces. From steel receive ready product – rolled iron.

Rolled iron (in metallurgy) - production of rolling manufacture (a beam, rails, pipes, sheets, strips, tapes etc.).

Rolling manufacture is reception from steel and other metals ­ by proskating rinks various products and half-finished products, and also additional processing of metals for the purpose of improvement of quality.

In our republic there are large supplies of iron ore: Sokolov-Sarbai, Lisakov, Ajat, Kashar, Atasu, Karazhal deposits. On stocks of iron ore Kazakhstan occupies in the world the eighth, and in the CIS - the third place.

The Sokolov-Sarbai deposit has been opened in 1949 by the pilot M.Surgutanov. The biggest iron-ore industrial complex ­ - the Sokolov mountain-concentrating industrial complex processing ­ 30-40 million t of iron ore in year lets out high-quality ­iron-ore concentrates. Lisakov, Ajat, Kashar mountain-concentrating industrial complexes make flux ­ agglomerates which are raw materials for cast-iron melt. Besides, these deposits provide with iron ore the Ural metallurgical industrial complex.

Sokolov-Sarbai, Kashar, Lisakov, Ajat deposits ­ on stocks of iron ores can be compared to known ­ deposits in the world in Lorraine and Krivoi Rog.

One of demanded kinds of raw materials for ferrous metallurgy ­ is manganous ore (deposits of Zhezdy, Karazhal and Ushkatyn). In ferrous metallurgy Topar lime, Alekseev dolomite, refractory clay and quartzitic ore are applied.

As a part of ferrous metallurgy following types of the enterprises are allocated­:

1. Metal works of a full cycle, i.e. making cast-iron­, steel and rolled iron (sometimes their structure includes also extraction of iron ore);

2. Steel-smelting and steel-rolling factories ("reefficient metallurgy­");

3. Manufacture of ferroalloys - alloys of iron with chrome, manganese­, silicon and other elements; these alloys are used further ­ at melt of steel for giving to it of demanded properties;

4. Small metallurgy - steel and rolled iron manufacture at machine-building ­ factories;

5. Without blast furnace metallurgy - manufacture of iron by a method of direct ­ restoration (from iron-ore in electric furnaces).

Ferrous metallurgy bases in Kazakhstan have been put in 1938. After opening in the Aktobe area nickel and chromite mines in Aktobe the factory of ferroalloys has been constructed. On stocks of chromite Kazakhstan occupies in the CIS the first (97 % of all stock), and in the world - the second place (after the republic of South Africa). For reception of a high-quality steel use the chromite ores steady against action of high temperatures. In days of the Great Patriotic War (1943) the ­ Aktobe factory of ferroalloys ­ has made for the first time for manufacturing of tank cases­, trunks of guns and well-known "katyushas" ­ Kazakhstan ferrochromes. Now the ­ foreign countries, many enterprises of republic use ferroalloys of the Aktobe factory.

The concentration of ores of the ferrous metals, coked coal and iron ­ ore in the Central Kazakhstan has created conditions for development ­ of powerful iron and steel industry. So, in 1960 in blast furnaces of the Karaganda metallurgical industrial complex in Temirtau the first cast-iron that became significant event ­ in republic life has been received­. Now the Karaganda metallurgical industrial complex (in Kazakhstan) makes the biggest ­ for machine-building factories cast-iron, a steel, rolled iron, high-quality ­ rolling sheet, coke and agglomerate for blast furnaces, various chemical production, domain slag, rails, pipes ­ and set of other production, is engaged in continuous moulding ­ of a steel in martin furnaces. This base of ferrous metallurgy is called the Kazakhstan Magnitogorsk.

On volume of an industrial output of ferrous metallurgy Kazakhstan ­ among the CIS countries takes the third place (after Russia and the Ukraine).

At the Karaganda metallurgical industrial complex there is begun building ­ of one more shop - a new camp which will let out ­ rolling sheets. Now the Karaganda metallurgical industrial complex which English firm "Ispat" operates is renamed in "Ispat-Karmet".

The Karaganda metallurgical industrial complex of full cycle of manufacture ­("Arselor Mittal of Temirtau") - unique in Kazakhstan - gives 100 % of cast-iron and 97 % of steel. It takes on capacity 7th place in the CIS.

For improvement of quality of cast-iron in Aksu the factory of ferroalloys has been constructed. Chromite ores arrive here from Aktobe areas, coke - from Karaganda, supply by the electric power is carried out by the Aksu state district power station.

Now in Taraz works the third ferro-alloy factory in Kazakhstan which is letting out ferro-manganese. The Zhambyl state district power station provides it with electric power. Aksu, Aktobe and Taraz ferro-alloy factories let out high-quality steel for mechanical engineering. On stocks of manganous ore Kazakhstan among the CIS countries concedes only to the Ukraine, in the world takes the third place after the USA and the Ukraine.

In the near future the civil-engineering design of factory ­ of full metallurgical cycle on the basis of Aksu factory and Sokolov-Sarbai mountain-concentrating industrial complex is provided­.

In Temirtau the metal works on a meltdown ­ of steel breakage will be constructed­.

In connection with increase of quantity and capacities of the enterprises of ferrous metallurgy there was a necessity for an establishment on the enterprises of dust removal devices and filters which should reduce considerably quantity of the harmful gases ­ which are thrown out in atmosphere.

Dedusters establish on pipes of considerable height that not the harmful substances detained by the filter arrived in an upper atmosphere. It considerably reduces pollution of top layer of the earth and waters.

Now before the industrial enterprises there is a ­ problem of introduction of technologies without waste.