Steel manufacturing and foundries play a critical role in processing raw materials like iron ore, coke, and limestone into high-quality metal products used in various industries. These facilities are major consumers of mined materials and have their own set of processes that generate dust and other byproducts. Key Processes in Steel Manufacturing - Blast Furnaces: Used to convert iron ore into molten iron through smelting. - Basic Oxygen Furnaces (BOFs) or Electric Arc Furnaces (EAFs): Used to refine molten iron or recycle scrap metal into steel. - Continuous Casting and Rolling Mills: Transform molten steel into sheets, bars, or other shapes. Foundry Operations Foundries produce cast metal components by melting metals and pouring them into molds. Common steps include: - Molding: Sand or metal molds are prepared to shape molten metal. - Melting: Furnaces such as cupolas, induction furnaces, or gas-fired furnaces melt raw materials or recycled scrap. - Casting: Molten metal is poured into molds and allowed to solidify. - Finishing: Cleaning, grinding, and machining the castings to the final specification. Dust and Emission Sources Both steel manufacturing and foundries produce substantial amounts of dust and airborne particles at various stages: - Material Handling: Iron ore, coal, and limestone storage, conveyors, and transfer points. - Furnaces: Emissions from blast and induction furnaces. - Casting and Cooling: Dust and fumes from molten metal pouring and cooling processes. - Finishing Operations: Grinding, cutting, and polishing of cast metal components. Key Mined Materials Used - Iron Ore: The primary raw material for steel production. - Coke: Derived from coal and used as a fuel and reducing agent in smelting. - Limestone: Used as a flux to remove impurities during the smelting process. - Recycled Scrap Metal: Increasingly used in EAFs for sustainable steel production. Challenges and Dust Control Needs The heavy dust and emissions generated by these processes require robust control systems to: - Protect worker health and safety. - Ensure equipment longevity. - Comply with environmental regulations.