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82-650: Iron ore was discovered in what is now the Iron Mountain area in 1878. Development was rapid: Iron Mountain was platted in 1879 and the Chapin Mine Company was formed the same year. The Chapin Mine proved to be the most productive in the Menominee Range, but part of the orebody was underneath a cedar swamp and water seepage proved to be an ongoing problem. Ground pumps were used at first, but as

164-548: A "relic for sightseers to visit." The county demolished the building housing the pumping engine and painted the engine to make it more attractive to tourists. The engine was nearly scrapped during World War II for its metal content, and indeed the steel frame shaft housing standing nearby was dismantled, but local sentiment saved the pumping engine. In 1978, the county turned it over to the Menominee Range Historical Foundation, who constructed

246-528: A 33% to 40% recovery of magnetite by weight, to produce a concentrate grading in excess of 64% iron by weight. The typical magnetite iron ore concentrate has less than 0.1% phosphorus , 3–7% silica , and less than 3% aluminium . As of 2019, magnetite iron ore is mined in Minnesota and Michigan in the United States , eastern Canada , and northern Sweden . Magnetite-bearing banded iron formation

328-399: A Watt engine, steam is admitted throughout the piston's power stroke. At the end of the stroke, the steam is exhausted, and any remaining energy is wasted in the condenser, where the steam is cooled back to water. In a Cornish engine, by contrast, the intake valve is shut off midway through the power stroke, allowing the steam already in that part of the cylinder to expand through the rest of

410-696: A benchmark to be followed by the rest of the industry. Singapore Mercantile Exchange (SMX) has launched the world's first global iron ore futures contract, based on the Metal Bulletin Iron Ore Index (MBIOI) which uses daily price data from a broad spectrum of industry participants and independent Chinese steel consultancy and data provider Shanghai Steelhome's widespread contact base of steel producers and iron ore traders across China. The futures contract has seen monthly volumes over 1,500,000 t (1,500,000 long tons; 1,700,000 short tons) after eight months of trading. This move follows

492-483: A blast furnace more efficient. Others are added because they make the iron more fluid, harder, or give it some other desirable quality. The choice of ore, fuel, and flux determines how the slag behaves and the operational characteristics of the iron produced. Ideally, iron ore contains only iron and oxygen. In reality, this is rarely the case. Typically, iron ore contains a host of elements which are often unwanted in modern steel. Cornish engine A Cornish engine

574-403: A duty of nearly 50 million, but its efficiency then fell back. A test was carried out between a Trevithick type single-cylinder engine and a Woolf compound engine at Wheal Alfred in 1825, when both achieved a duty of slightly more than 40 million. The next improvement was achieved in the late 1820s by Samuel Grose , who decreased the heat loss by insulating the pipes, cylinders, and boilers of

656-663: A museum around it in 1982-83. It was designated a Michigan State Historic Site in 1958, and was listed on the National Register of Historic Places in 1981. In 1987, the American Society of Mechanical Engineers designated the pump a National Historic Mechanical Engineering Landmark . The museum housing the pump, known as the Cornish Pumping Engine and Mining Museum, also displays a varied collection of mining equipment used in local iron mines;

738-424: A premium price. Due to the high density of hematite relative to associated silicate gangue, hematite beneficiation usually involves a combination of beneficiation techniques. One method relies on passing the finely-crushed ore over a slurry containing magnetite or other agent such as ferrosilicon which increases its density. When the density of the slurry is properly calibrated, the hematite will sink and

820-453: A relatively low-grade ore, they are also inexpensive to collect, as they do not have to be mined. Because of this, companies such as Magnetation have started reclamation projects where they use iron ore tailings as a source of metallic iron. The two main methods of recycling iron from iron ore tailings are magnetizing roasting and direct reduction. Magnetizing roasting uses temperatures between 700 and 900 °C (1,292 and 1,652 °F) for

902-538: A single pump. The engine was restored to working order between 1985 and 2000, although it is now operated by an oil-filled hydraulic system, since restoration to steam operation was not viable. The Cornish Engines Preservation Committee , an early industrial archaeology organisation, was formed in 1935 to preserve the Levant winding engine . The committee was later renamed for Richard Trevithick . They acquired another winding engine and two pumping engines. They publish

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984-616: A source of iron ore. Prior to the industrial revolution, most iron was obtained from widely-available goethite or bog ore , for example, during the American Revolution and the Napoleonic Wars . Historically, much of the iron ore utilized by industrialized societies has been mined from predominantly hematite deposits with grades of around 70% Fe. These deposits are commonly referred to as "direct shipping ores" or "natural ores". Increasing iron ore demand, coupled with

1066-515: A sub-atmospheric pressure engine. In a parallel development Arthur Woolf developed the compound steam engine , in which the steam expanded in two cylinders successively, each of which were at pressures above atmospheric. When Trevithick left for South America in 1816 he passed his patent right of his latest invention to William Sims , who built or adapted a number of engines, including one at Wheal Chance operating at 40 pounds per square inch (280 kPa) above atmospheric pressure , which achieved

1148-606: A switch to index-based quarterly pricing by the world's three largest iron ore miners— Vale , Rio Tinto , and BHP —in early 2010, breaking a 40-year tradition of benchmark annual pricing. Iron is the most abundant element on earth but not in the crust. The extent of the accessible iron ore reserves is not known, though Lester Brown of the Worldwatch Institute suggested in 2006 that iron ore could run out within 64 years (that is, by 2070), based on 2% growth in demand per year. Geoscience Australia calculates that

1230-418: A time of under 1 hour to produce an iron concentrate (Fe 3 O 4 ) to be used for iron smelting. For magnetizing roasting, it is important to have a reducing atmosphere to prevent oxidization and the formation of Fe 2 O 3 because it is harder to separate as it is less magnetic. Direct reduction uses hotter temperatures of over 1,000 °C (1,830 °F) and longer times of 2–5 hours. Direct reduction

1312-655: A typically titanium -bearing magnetite, often with vanadium . These ores form a niche market, with specialty smelters used to recover the iron, titanium, and vanadium. These ores are beneficiated essentially similarly to banded iron formation ores, but usually are more easily upgraded via crushing and screening . The typical titanomagnetite concentrate grades 57% Fe, 12% Ti, and 0.5% V 2 O 5 . For every one ton of iron ore concentrate produced, approximately 2.5–3.0 tons of iron ore tailings will be discharged. Statistics show that there are 130 million tons of iron ore tailings discharged every year. If, for example,

1394-659: A value of $ 2.3 billion. 46% of Canada's iron ore comes from the Iron Ore Company of Canada mine, in Labrador City , Newfoundland , with secondary sources including the Mary River Mine in Nunavut . According to the U.S. Geological Survey's 2021 Report on iron ore, India is estimated to produce 59,000,000 t (58,000,000 long tons; 65,000,000 short tons) of iron ore in 2020, placing it as

1476-471: Is 24 inches (61 cm) in diameter and the high and low pressure steam are 50 inches (130 cm) and 100 inches (250 cm) in diameter, respectively, both having a stroke of 10 feet (3.0 m). At the Ludington "C" shaft location, the pumping engine was connected via a 7 inches (18 cm) diameter shaft to a series of eight pumps, the deepest of which was 1,500 feet (460 m) below ground (at

1558-511: Is a high-volume, low-margin business, as the value of iron is significantly lower than base metals. It is highly capital intensive, and requires significant investment in infrastructure such as rail in order to transport the ore from the mine to a freight ship. For these reasons, iron ore production is concentrated in the hands of a few major players. World production averages 2,000,000,000 t (2.0 × 10 long tons; 2.2 × 10 short tons) of raw ore annually. The world's largest producer of iron ore

1640-591: Is a type of steam engine developed in Cornwall , England, mainly for pumping water from a mine. It is a form of beam engine that uses steam at a higher pressure than the earlier engines designed by James Watt . The engines were also used for powering man engines to assist the underground miners' journeys to and from their working levels, for winching materials into and out of the mine, and for powering on-site ore stamping machinery . Cornwall has long had tin , copper and other metal ore mines, but if mining

1722-428: Is expected to rise by a CAGR of 2% between 2023 and 2027, and industry analyst Fitch Solutions forecasted in 2021 that Brazil's annual production will reach 592,000,000 t (583,000,000 long tons; 653,000,000 short tons) by 2030. In 2017, Canadian iron ore mines produced 49,000,000 t (48,000,000 long tons; 54,000,000 short tons) of iron ore in concentrate pellets and 13.6 million tons of crude steel. Of

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1804-510: Is followed by Japan and Korea, which consume a significant amount of raw iron ore and metallurgical coal . In 2006, China produced 588,000,000 t (579,000,000 long tons; 648,000,000 short tons) of iron ore, with an annual growth of 38%. Over the last 40 years, iron ore prices have been decided in closed-door negotiations between the small handful of miners and steelmakers which dominate both spot and contract markets. Until 2006, prices were determined in annual benchmark negotiations between

1886-603: Is in the iron ranges around Lake Superior . These iron ranges occur in Minnesota and Michigan, which combined accounted for 93% of the usable iron ore produced in the United States in 2014. Seven of the nine operational open pit mines in the United States are located in Minnesota as well as two of the three tailings reclamation operations. The other two active open pit mines were located in Michigan . In 2016, one of

1968-709: Is mined extensively in Brazil as of 2019, which exports significant quantities to Asia , and there is a nascent and large magnetite iron ore industry in Australia . Direct-shipping iron ore (DSO) deposits (typically composed of hematite ) are currently exploited on all continents except Antarctica , with the largest intensity in South America , Australia, and Asia. Most large hematite iron ore deposits are sourced from altered banded iron formations and (rarely) igneous accumulations. DSO deposits are typically rarer than

2050-463: 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 ". Metallic iron is virtually unknown on

2132-481: Is the Brazilian mining corporation Vale , followed by Australian companies Rio Tinto Group and BHP . A further Australian supplier, Fortescue Metals Group Ltd, has helped bring Australia's production to first in the world. The seaborne trade in iron ore—that is, iron ore to be shipped to other countries—was 849,000,000 t (836,000,000 long tons; 936,000,000 short tons) in 2004. Australia and Brazil dominate

2214-592: Is the last Cornish engine to have worked commercially in Cornwall. It was moved to Poldark in 1972. The Cruquius pumping station in the Netherlands contains a Cornish engine with the largest diameter cylinder ever built for a Cornish engine, at 3.5 metres (140 inches) diameter. The engine, which was built by Harvey & Co in Hayle , Cornwall, has eight beams connected to the one cylinder , each beam driving

2296-400: Is to take place at greater depths, a means to dewater the mine must be found. Lifting the weight of water up from the depths requires great amounts of work input. This energy may be weakly supplied by horse power or a waterwheel to operate pumps, but horses have limited power and waterwheels need a suitable stream of water. Accordingly, the innovation of coal-fired steam power to work pumps

2378-425: Is used to produce sponge iron (Fe) to be used for steel-making. Direct reduction requires more energy, as the temperatures are higher and the time is longer and it requires more reducing agent than magnetizing roasting. Lower-grade sources of iron ore generally require beneficiation , using techniques like crushing, milling , gravity or heavy media separation , screening, and silica froth flotation to improve

2460-467: Is usually found in the form of magnetite ( Fe 3 O 4 , 72.4% Fe), hematite ( Fe 2 O 3 , 69.9% Fe), goethite ( FeO(OH) , 62.9% Fe), limonite ( FeO(OH)·n(H 2 O) , 55% Fe), or siderite ( FeCO 3 , 48.2% Fe). Ores containing very high quantities of hematite or magnetite, typically greater than about 60% iron, are known as natural ore or direct shipping ore , and can be fed directly into iron-making blast furnaces . Iron ore

2542-905: The Chichester Range , the Hamersley Range and Koolyanobbing , Western Australia . Other types of ore are coming to the fore recently, such as oxidised ferruginous hardcaps, for instance laterite iron ore deposits near Lake Argyle in Western Australia. The total recoverable reserves of iron ore in India are about 9,602,000,000 t (9.450 × 10 long tons; 1.0584 × 10 short tons) of hematite and 3,408,000,000 t (3.354 × 10 long tons; 3.757 × 10 short tons) of magnetite . Chhattisgarh , Madhya Pradesh , Karnataka , Jharkhand , Odisha , Goa , Maharashtra , Andhra Pradesh , Kerala , Rajasthan , and Tamil Nadu are

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2624-511: The Cornish Mines and Engines museum on the site of East Pool mine near the town of Pool, Cornwall . Another example is at Poldark Mine at Trenear, Cornwall – a Harvey of Hayle Cornish Beam Engine from about 1840–1850, originally employed at Bunny Tin Mine and later at Greensplat China Clay Pit, both near St Austell. It no longer works as a steam engine but is instead moved by a hydraulic mechanism. In use at Greensplat until 1959, it

2706-602: The Earth 's surface except as iron-nickel alloys from meteorites and very rare forms of deep mantle xenoliths . Although iron is the fourth-most abundant element in the Earth's crust , composing about 5%, the vast majority is bound in silicate or, more rarely, carbonate minerals, and smelting pure iron from these minerals would require a prohibitive amount of energy. Therefore, all sources of iron used by human industry exploit comparatively rarer iron oxide minerals, primarily hematite . Prehistoric societies used laterite as

2788-564: The Pilbara region of Western Australia is approximately 844,000,000 t (831,000,000 long tons; 930,000,000 short tons) per year and rising. Gavin Mudd ( RMIT University ) and Jonathon Law ( CSIRO ) expect it to be gone within 30–50 years and 56 years, respectively. These 2010 estimates require ongoing review to take into account shifting demand for lower-grade iron ore and improving mining and recovery techniques (allowing deeper mining below

2870-407: The silicate mineral fragments will float and can be removed. Iron is the world's most commonly used metal—steel, of which iron ore is the key ingredient, represents almost 95% of all metal used per year. It is used primarily in structures, ships, automobiles, and machinery. Iron-rich rocks are common worldwide, but ore-grade commercial mining operations are dominated by the countries listed in

2952-420: The 13,600,000 t (13,400,000 long tons; 15,000,000 short tons) of steel 7,000,000 t (6,900,000 long tons; 7,700,000 short tons) was exported, and 43,100,000 t (42,400,000 long tons; 47,500,000 short tons) of iron ore was exported at a value of $ 4.6 billion. Of the iron ore exported, 38.5% of the volume was iron ore pellets with a value of $ 2.3 billion, and 61.5% was iron ore concentrates with

3034-691: The 62–64% Fe range. Granite and ultrapotassic igneous rocks were sometimes used to segregate magnetite crystals and form masses of magnetite suitable for economic concentration. A few iron ore deposits, notably in Chile , are formed from volcanic flows containing significant accumulations of magnetite phenocrysts . Chilean magnetite iron ore deposits within the Atacama Desert have also formed alluvial accumulations of magnetite in streams leading from these volcanic formations. Some magnetite skarn and hydrothermal deposits have been worked in

3116-800: The Chapin Mine Steam Pump Engine is popularly known as "The Cornish Pump", it is not actually a Cornish engine , which lacks the rotating parts (connecting rod, crank and flywheel) seen in the Chapin Engine. Rather, the name comes from the similarity between the Chapin engine and those used in tin mines in Cornwall in the 19th century. 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

3198-429: The United States is estimated to have accounted for 2% of the world's iron ore output. In the United States there are twelve iron ore mines, with nine being open pit mines and three being reclamation operations. There were also ten pelletizing plants, nine concentration plants, two direct-reduced iron (DRI) plants, and one iron nugget plant that were operating in 2014. In the United States the majority of iron ore mining

3280-490: The atmosphere. This differed from the Watt steam engine, which moved the condensing steam from the cylinder to a condenser separate from the cylinder; hence Watt's engine depended on the creation of a vacuum when the steam was condensed. Trevithick's later engines (in the 1810s) combined the two principles, starting with high-pressure steam which was then passed to the other side of the piston, where it condensed and there it acted as

3362-416: The boiler pressure would have made an engine more powerful without increasing its efficiency. The key advance was allowing the steam to expand in the cylinder. While James Watt had conceived of the idea of allowing expansive working of steam—and included it in his 1782 patent, he realized that the low steam pressure of his application made the improvement in efficiency negligible, and so did not pursue it. In

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3444-411: The concentration of the ore and remove impurities. The results, high-quality fine ore powders, are known as fines. Magnetite is magnetic , and hence easily separated from the gangue minerals and capable of producing a high-grade concentrate with very low levels of impurities. The grain size of the magnetite and its degree of commingling with the silica groundmass determine the grind size to which

3526-533: The country's " economic demonstrated resources " of iron currently amount to 24 gigatonnes , or 24,000,000,000 t (2.4 × 10 long tons; 2.6 × 10 short tons). Another estimate places Australia's reserves of iron ore at 52,000,000,000 t (5.1 × 10 long tons; 5.7 × 10 short tons), or 30% of the world's estimated 170,000,000,000 t (1.7 × 10 long tons; 1.9 × 10 short tons), of which Western Australia accounts for 28,000,000,000 t (2.8 × 10 long tons; 3.1 × 10 short tons). The current production rate from

3608-422: The cycle, completely pausing at one point while having rapid motion on the down stroke, making it unsuitable for rotary motion and most industrial applications. This also requires some unusual valve gear , see Cornish engine valve gear . The Cornish cycle operates as follows. Starting from a condition during operation with the piston at the top of the cylinder, the cylinder below the piston full of steam from

3690-584: The depletion of high-grade hematite ores in the United States, led after World War II to the development of lower-grade iron ore sources, principally the use of magnetite and taconite . Iron ore mining methods vary by the type of ore being mined. There are four main types of iron ore deposits worked currently, depending on the mineralogy and geology of the ore deposits. These are magnetite, titanomagnetite , massive hematite, and pisolitic ironstone deposits. The origin of iron can be ultimately traced to its formation through nuclear fusion in stars, and most of

3772-441: The engines, improving the duty to more than 60 million at Wheal Hope and later to almost 80 million at Wheal Towan . Nevertheless, the best duty was usually a short-lived achievement due to general deterioration of machinery, leaks from boilers, and the deterioration of boiler plates (meaning that pressure had to be reduced). Minor improvements increased the duty somewhat, but the engine seems to have reached its practical limits by

3854-558: The entire installation cost an estimated $ 250,000. The pump began operation on January 3, 1893. An underground shift in 1896 misaligned the engine, and further shifts cracked the engine house and the surrounding ground. In 1899, the pumping engine was dismantled and stored away. In the meantime, the Chapin Mining Company had been expanding. In 1894, it acquired the nearby Hamilton and Ludington mines, both of which had been abandoned due to flooding problems. Chapin dewatered

3936-442: The gangue is separated during the beneficiation process and is removed as tailings . Taconite tailings are mostly the mineral quartz , which is chemically inert. This material is stored in large, regulated water settling ponds. The key parameters for magnetite ore being economic are the crystallinity of the magnetite, the grade of the iron within the banded iron formation host rock, and the contaminant elements which exist within

4018-800: The groundwater table). Brazil is the second-largest producer of iron ore after Australia, accounting for 16% of the world's iron ore production. After a somewhat sluggish production volume 2010-2020, partly due to the Mariana dam disaster in 2015 and the Brumadinho dam disaster in 2019, which halted the production at the two involved mines, production has increased steadily since 2021, when Brazil produced 431,000,000 t (424,000,000 long tons; 475,000,000 short tons). In 2022 it increased to 435,000,000 t (428,000,000 long tons; 480,000,000 short tons) and in 2023 to 440,000,000 t (430,000,000 long tons; 490,000,000 short tons). The Brazilian production

4100-463: The improvement of the steam engine came from Cornwall due to the high price of coal there, but both capital and maintenance costs were higher than a Watt steam engine. This long delayed the installation of Cornish engines outside Cornwall. A secondhand Cornish engine was installed at East London Waterworks in 1838, and compared to a Watt engine with favourable results, because the price of coal in London

4182-450: The iron and carbon smelting must be kept in an oxygen-deficient (reducing) state to promote the burning of carbon to produce CO and not CO 2 . The inclusion of even small amounts of some elements can have profound effects on the behavioral characteristics of a batch of iron or the operation of a smelter. These effects can be both good and bad, some catastrophically bad. Some chemicals are deliberately added, such as flux, which makes

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4264-413: The iron from the oxygen, a stronger elemental bond must be presented to attach to the oxygen. Carbon is used because the strength of a carbon-oxygen bond is greater than that of the iron-oxygen bond at high temperatures. Thus, the iron ore must be powdered and mixed with coke , to be burnt in the smelting process. Carbon monoxide is the primary ingredient of chemically stripping oxygen from iron. Thus,

4346-895: The iron is thought to have originated in dying stars that are large enough to explode as supernovae . The Earth's core is thought to consist mainly of iron, but this is inaccessible from the surface. Some iron meteorites are thought to have originated from asteroids 1,000 km (620 mi) in diameter or larger. Banded iron formations (BIFs) are sedimentary rocks containing more than 15% iron composed predominantly of thinly-bedded iron minerals and silica (as quartz ). Banded iron formations occur exclusively in Precambrian rocks, and are commonly weakly-to-intensely metamorphosed . Banded iron formations may contain iron in carbonates ( siderite or ankerite ) or silicates ( minnesotaite , greenalite , or grunerite ), but in those mined as iron ores, oxides ( magnetite or hematite ) are

4428-530: The largest collection of Cornish engines in the world. At Crofton Pumping Station , in Wiltshire are two Cornish engines, one of which (the 1812 Boulton and Watt ) is the "oldest working beam engine in the world still in its original engine house and capable of actually doing the job for which it was installed", that of pumping water to the summit pound of the Kennet and Avon Canal . Two examples also survive at

4510-423: The magnetite concentrate. The size and strip ratio of most magnetite resources is irrelevant, as a banded iron formation can be hundreds of meters thick, extend hundreds of kilometers along strike , and can easily come to more than three billion or more tonnes of contained ore. The typical grade of iron at which a magnetite-bearing banded iron formation becomes economic is roughly 25% iron, which can generally yield

4592-476: The magnetite-bearing BIF or other rocks which form its main source, or protolith rock, but are considerably cheaper to mine and process as they require less beneficiation due to the higher iron content. However, DSO ores can contain significantly higher concentrations of penalty elements, typically being higher in phosphorus, water content (especially pisolite sedimentary accumulations), and aluminium ( clays within pisolites). Export-grade DSO ores are generally in

4674-399: The main iron ore producers ( BHP Billiton , Rio Tinto , and Vale S.A. ) and Japanese importers. In 2006, Chinese company Baosteel began handling negotiations for the importer side. The Chinese government replaced Baosteel with China Iron and Steel Association as lead negotiator in 2009. Traditionally, the first deal reached between these the major producers and the major importers sets

4756-410: The mid-1840s. With pressures of up to 50 pounds per square inch (340 kPa), the forces are likely to have caused machinery breakages. The same improvements in duty occurred in engines operating Cornish stamps and whims , but generally came slightly later. In both cases the best duty was lower than for pumping engines, particularly so for whim engines, whose work was discontinuous. The impetus for

4838-503: The mine owners a royalty based on a share of the fuel saving. The fuel efficiency of an engine was measured by its "duty", expressed in the work (in foot-pounds ) generated by a bushel (94 pounds (43 kg)) of coal. Early Watt engines had a duty of 20 million, and later ones over 30 million. The principal advantage of the Cornish engine was its increased efficiency, accomplished by making more economical use of higher-pressure steam. At

4920-410: The mine tailings contain an average of approximately 11% iron, there would be approximately 1.41 million tons of iron wasted annually. These tailings are also high in other useful metals such as copper , nickel , and cobalt , and they can be used for road-building materials like pavement and filler and building materials such as cement, low-grade glass, and wall materials. While tailings are

5002-551: The museum is open to the public. The Chapin Mine Steam Pump Engine is a vertical tandem compound steam engine. At its maximum speed of 10 rpm, it produced over 1,200 horsepower (890 kW), and during operation required 11,000 short tons (10,000 t) of coal per year to operate. It is 54 feet (16 m) tall with a flywheel 40 feet (12 m) in diameter, weighing 164 short tons (149 t). The entire engine weighs 600 short tons (540 t). The drive shaft

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5084-442: The original Chapin "D" shaft location, the depth was only 600 feet (180 m)). Each pump had plungers 28 inches (71 cm) in diameter with a stroke of 10 feet (3.0 m). Water was pumped by each pump through a vertical pipe to a discharge tank just beneath the next pump in series, and thus was carried in eight steps to the surface. The total capacity of the pump system was 3,400 US gallons (13,000 L) per minute. Although

5166-667: The other mines and made underground connections to the Chapin Mine. The Chapin Mining Company was purchased by the Oliver Iron Mining Company, a subsidiary of U.S. Steel , in 1901. In 1907, Oliver reassembled the pumping engine and moved it to its current location near the site of the Ludington Mine "C" shaft. They constructed a corrugated metal building on a red sandstone foundation to house

5248-509: The past as high-grade iron ore deposits requiring little beneficiation . There are several granite-associated deposits of this nature in Malaysia and Indonesia . Other sources of magnetite iron ore include metamorphic accumulations of massive magnetite ore such as at Savage River , Tasmania , formed by shearing of ophiolite ultramafics . Another, minor, source of iron ores are magmatic accumulations in layered intrusions which contain

5330-401: The previous stroke, the boiler at normal working pressure, and the condenser at normal working vacuum, The next stroke may occur immediately, or it may be delayed by a timing device such as a cataract , if it was not necessary for the engine to work at its maximum rate, reducing the rate of operation saved fuel. The engine is single-acting , and the steam piston is pulled up by the weight of

5412-480: The principal Indian producers of iron ore. World consumption of iron ore grows 10% per year on average with the main consumers being China, Japan, Korea, the United States, and the European Union. China is currently the largest consumer of iron ore, which translates to be the world's largest steel producing country. It is also the largest importer, buying 52% of the seaborne trade in iron ore in 2004. China

5494-481: The principal iron mineral. Banded iron formations are known as taconite within North America. The mining involves moving tremendous amounts of ore and waste. The waste comes in two forms: non-ore bedrock in the mine ( overburden or interburden locally known as mullock), and unwanted minerals, which are an intrinsic part of the ore rock itself ( gangue ). The mullock is mined and piled in waste dumps , and

5576-417: The pump piston and rodding. Steam may be supplied at a pressure of up to 50 pounds per square inch (340 kPa). Real photos showing the components of the schematic design ( East Pool mine Tailer's shaft Harvey's Engine): The Cornish engine depended on the use of steam pressure above atmospheric pressure, as devised by Richard Trevithick in the 19th century. His early puffer engines discharged steam into

5658-473: The pumping engine. The pump served the combined needs of the Chapin, Ludington and Hamilton mines until 1914, when it was replaced with electric pumps. By the time the Chapin Mine closed in 1932, it had produced over 27 million tons of iron ore, the most in the Menominee Iron Range. Two years later, the Oliver Iron Mining Company donated the Chapin Mine Steam Pump Engine to Dickinson County as

5740-429: The quartz is left behind when the resultant powder is passed under a magnetic separator. Generally, most magnetite banded iron formation deposits must be ground to between 32 and 45 μm (0.0013 and 0.0018 in) in order to produce a low-silica magnetite concentrate. Magnetite concentrate grades are generally in excess of 70% iron by weight and usually are low in phosphorus, aluminium, titanium, and silica and demand

5822-407: The rock must be comminuted to enable efficient magnetic separation to provide a high-purity magnetite concentrate. This determines the energy inputs required to run a milling operation. Mining of banded iron formations involves coarse crushing and screening, followed by rough crushing and fine grinding to comminute the ore to the point where the crystallized magnetite and quartz are fine enough that

5904-446: The seaborne trade, with 72% of the market. BHP, Rio and Vale control 66% of this market between them. In Australia , iron ore is won from three main sources: pisolite " channel iron deposit " ore derived by mechanical erosion of primary banded-iron formations and accumulated in alluvial channels such as at Pannawonica, Western Australia ; and the dominant metasomatically altered banded iron formation -related ores such as at Newman ,

5986-464: The seventh largest global center of iron ore production, behind Australia, Brazil, China, India, Russia, and South Africa. Producers of iron ore in Ukraine include Ferrexpo , Metinvest , and ArcelorMittal Kryvyi Rih . In 2014, mines in the United States produced 57,500,000 t (56,600,000 long tons; 63,400,000 short tons) of iron ore with an estimated value of $ 5.1 billion. Iron mining in

6068-451: The seventh-largest global center of iron ore production, behind Australia, Brazil, China, Russia, South Africa, and Ukraine. India's iron ore production in 2023 was 285,000,000 metric tonnes and was the fourth largest producer in the world. According to the U.S. Geological Survey's 2021 Report on iron ore, Ukraine is estimated to have produced 62,000,000 t (61,000,000 long tons; 68,000,000 short tons) of iron ore in 2020, placing it as

6150-407: The shaft depth increased, so did the problems. In 1889, after a number of accidents, the mining company commissioned a water pump from the E. P. Allis Company of Milwaukee, Wisconsin (now Allis-Chalmers ). The company's chief engineer, Edwin P. Reynolds, designed a " Cornish Pump " similar to those used in tin mines in Cornwall, England . The company constructed the pump in 1890-91, after which it

6232-518: The stroke to a lower pressure. This results in the capture of a greater proportion of its energy, and less heat being lost to the condenser, than in a Watt engine. Other characteristics include insulation of steam lines and the cylinder, and steam jacketing the cylinder, both of which had previously been used by Watt. Few Cornish engines remain in their original locations, the majority having been scrapped when their related industrial firm closed. The Cornish engine developed irregular power throughout

6314-401: The table aside. The major constraint to economics for iron ore deposits is not necessarily the grade or size of the deposits, because it is not particularly hard to geologically prove enough tonnage of the rocks exist. The main constraint is the position of the iron ore relative to market, the cost of rail infrastructure to get it to market, and the energy cost required to do so. Mining iron ore

6396-411: The time, improvements in efficiency were important in Cornwall because of the high cost of coal; there are no coal fields in Cornwall and all the coal used had to be brought in from outside the county. Increasing the boiler pressure above the very low, virtually atmospheric pressure steam used by James Watt was an essential element of the improvement in efficiency of the Cornish engine. Simply increasing

6478-602: The two mines shut down. There have also been iron ore mines in Utah and Alabama ; however, the last iron ore mine in Utah shut down in 2014 and the last iron ore mine in Alabama shut down in 1975. Iron ores consist of oxygen and iron atoms bonded together into molecules. To convert it to metallic iron, it must be smelted or sent through a direct reduction process to remove the oxygen. Oxygen-iron bonds are strong, and to remove

6560-527: Was even higher than in Cornwall. In the main textile manufacturing areas, such as Manchester and Leeds , the coal price was too low to make replacement economic. Only in the late 1830s did textile manufacturers begin moving to high-pressure engines, usually by adding a high-pressure cylinder, forming a compound engine, rather than following the usual Cornish practice. Several Cornish engines are preserved in England. The London Museum of Water & Steam has

6642-435: Was installed at Chapin Mine's "D" shaft. The pump engine was installed at the surface near a boiler, to minimize efficiency losses in steam transport and to prevent damage to the engine in case of an emergency shut-off. It was housed in a massive red sandstone pump house, 60 feet (18 m) high, 36 feet (11 m) by 42 feet (13 m) at the base, with a foundation 23 feet (7.0 m) thick. The pump itself cost $ 82,000, and

6724-527: Was more versatile and effective to the mining industry than primitive means. The mine Wheal Vor had one of the earliest Newcomen engines (in-cylinder condensing engines, utilising sub-atmospheric pressure) before 1714, but Cornwall has no coalfield and coal imported from south Wales was expensive. The cost of fuel for pumping was thus a significant part of mining costs. Later, many of the more efficient early Watt engines (using an external condenser) were erected by Boulton and Watt in Cornwall. They charged

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