Iron making. Iron ore is mined in around 50 countries – the largest producers are Australia, Brazil and China. Around 98% of iron ore is used in steelmaking. During the ironmaking process, a blast furnace is fed with the iron ore, coke and small quantities of fluxes (minerals, such as limestone, which are used to collect impurities).
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Iron oxides exist in seven main ores (raw, rocky minerals mined from Earth): Hematite (the most plentiful) Limonite (also called brown ore or bog iron) Goethite; Magnetite (black ore; the magnetic type of iron oxide, also called lodestone) Pyrite; Siderite; Taconite (a combination of hematite and magnetite). Different ores contain different amounts of iron.
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To evaluate an iron ore resource, develop processing routines for iron ore beneficiation, and understand the behavior of the ore during such processing, extensive mineralogical characterizations are required.
For this process, coking coal is turned into coke, an almost pure form of carbon, which is used as the main fuel and reductant in a blast furnace. Typically, it takes tonnes of iron ore and around 450kg of coke to produce a tonne of pig iron, the raw iron that comes out of a blast furnace.