The blast furnace is like a giant cooking pot where we heat things up until they change. First, we burn coke (a coal‑derived carbon) with oxygen from the air. This reaction releases a lot of heat (🔥) and produces carbon dioxide:
\$C + O2 \;\longrightarrow\; CO2\$
The hot furnace environment allows the CO₂ to react with more coke, turning it into carbon monoxide, which is a gas that loves to steal oxygen from iron oxides:
\$CO_2 + C \;\longrightarrow\; 2\,CO\$
Now the CO gas comes into contact with the iron ore (hematite, \$Fe2O3\$). The CO donates oxygen, leaving behind molten iron:
\$Fe2O3 + 3\,CO \;\longrightarrow\; 2\,Fe + 3\,CO_2\$
Limestone (\$CaCO_3\$) is added to the furnace to help remove impurities. At high temperatures it breaks down into calcium oxide (lime) and CO₂:
\$CaCO3 \;\xrightarrow{heat}\; CaO + CO2\$
The lime reacts with silica and other impurities in the ore to form a molten slag that floats on top of the molten iron. Think of it as the “clean‑up crew” that carries away unwanted materials:
\$CaO + SiO2 \;\longrightarrow\; CaSiO3\$ (slag)
| Step | Reaction |
|---|---|
| 1. Burning of coke | \$C + O2 \rightarrow CO2\$ |
| 2. CO₂ → CO | \$CO_2 + C \rightarrow 2\,CO\$ |
| 3. Iron oxide reduction | \$Fe2O3 + 3\,CO \rightarrow 2\,Fe + 3\,CO_2\$ |
| 4. Limestone decomposition | \$CaCO3 \xrightarrow{heat} CaO + CO2\$ |
| 5. Slag formation | \$CaO + SiO2 \rightarrow CaSiO3\$ |
Quick Quiz: Which gas is the real “oxygen thief” that helps turn iron ore into liquid iron? 🤔