This document summarizes an exam question from a past paper on the iron and steel industry in Pakistan. The question asks the student to: 1) Identify raw materials and inputs shown in a diagram of inputs to Pakistan Steel; 2) Describe two human inputs to production; 3) Explain why over 50% of Pakistan Steel's output is sent north to Punjab; and 4) Identify features showing it is a formal sector industry. The question tests the student's understanding of the key raw materials, processes, outputs and location factors of Pakistan's iron and steel industry.

1. IRON AND STEEL INDUSTRY
Courtesy: Class X, 2007

2. PROJECT LAYOUT
RAW MATERIALS
PROCESSES
OUTPUT[PRODUCTS]
USES OF PRODUCTS
LOCATION
IMPORTANCE OF LOCATION
PROBLEMS
Faced by Industry
Faced by people,
environment and economy.
QUESTION BANK [2000-2007]

3. WHAT IS STEEL AND IRON?
• Steel is a metal composed of iron plus varying
amounts of carbon as well as other elements
such as chromium, nickel, molybdenum,
zirconium, vanadium, tungsten.
• Different types of steel are produced by
adjusting the chemical composition and
adapting any of the different stages of the
steelmaking process, such as rolling, finishing
and heat treatment.

4. •Iron is a lustrous, silvery soft metal. It is
extracted from iron ore, and is almost never
found in the free elemental state. In order to
obtain elemental iron, the impurities must be
removed by chemical reduction.
• Iron is the main
component of steel, and
it is used in the
production of alloys or
solid solutions of various
metals, as well as some
non-metals, particularly
carbon.

5. RAW MATERIALS
1. IRON ORE
Iron ores are rocks and minerals
from which metallic iron can be
economically extracted. Iron
ore 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.

6. 2. MANGANESE
It is found as the free element in nature
(often in combination with iron), and in
many minerals. The free element is a
metal with important industrial metal
alloy uses. Manganese is essential to iron
and steel production by virtue of its
sulfur-fixing, deoxidizing, and alloying
properties.

7. 3. COKING COAL
Coke is a solid carbonaceous material derived from
destructive distillation of low-ash, low-sulfur bituminous
coal.
The volatile constituents of the coal—including water,
coal-gas, and coal-tar—are driven off by baking in an
airless oven at temperatures as high as 2,000 degrees
Celsius. This fuses together the
fixed carbon and residual ash.
Most coke in modern facilities
is produced in "by-product"
coke ovens, and the resultant
coke is used as the main fuel
in iron-making blast furnaces.

8. 4) LIMESTONE
Limestone is a sedimentary rock
composed largely of the mineral
calcite (calcium carbonate:
CaCO3).
5) WATER
Large quantities of water are
required in the steel making
process.

9. PROCESSES

11. STEEL MAKING
Heating in coke ovens = Ore, coke and stone
Volatile components of introduced regularly in the
bituminous coal removed. blast furnace. These are
Coke remains as partially heated by rising hot gases.
graphitized solid residue.
Carbon monoxide react with
iron oxides = Form metallic
iron and carbon dioxide.
The iron melts and dissolves
carbon as it percolates
through the coke column.
By the time it reaches the hearth, it
Liquid slag, composed of gangue minerals is saturated with carbon and
and oxide components of stone, floats on the contains silicon, phosphorus
liquid iron and is separated from the molten manganese and sulphur. The stone
metal during furnace tapping. The coke does and ore form a low-melting, free-
not melt; it burns on contact with the running liquid slag, which absorbs
pressured, preheated air ("blast") entering most of the sulphur entering the
through the tuyères located just above the furnace (coke is the main sulphur
hearth. source).

12. OUTPUTS and USES
1) Steel billets
Manufacturing plain, deformed,
twisted and ribbed bars. Steel
sections: rails, angles, joints,
channels, squares, flat bars,
rods, wire rods, bailing hoops,
tees and chains etc. seamless
pipes. machine components.
Forging and stamping. spring
steel flat bars.
Billets are used to make different bars…which are used in
making railways, machine parts and chains etc.

13. 2) Hot Rolled Products
Seam Welded Pipes for Gas/Water/Oil.
Storage Tanks, Vessels, Containers.
Ships/Barges, Launches & Floating Structures.
Fabricated Sections/Structures.
General Purpose Sheets/Plates.
Wheel Rims. Formed Sections, Steel Flooring and
Cold Rolled Products.
Hot rolled carbon steel coils are
used for welded pipes,
wheel rims and ships etc.

14. 3) Cold Rolled Sheets/Coils.

15. 4) Galvanized Products
Automobiles, Roofing, Shuttering,
Panelling, Manufacture of buckets,
utensils, cans, containers Desert
coolers, Air conditioners, Water coolers,
Fresh water tanks, etc, Domestic appliances.
Galvanized steel is used for automobiles, air-
conditioners, water tanks etc.

16. 5) Coke
•Widely used as a fuel by foundries
in cupolas for melting iron scrap
and pig iron.
•In sugar mills employing the
carbonizing process.
•For making chemicals/calcium
carbide.
•Used in the pharmaceutical
industries.
•Coke breeze is used for steam
generation in boiler houses.
•Used in Steel making for carbon
adjustment.
•Coke fuel is used in sugar mills,
pharmaceutical companies and in
generators.

17. 7) Pig Iron

18. BY PRODUCTS
Coal tar Granulated slag
Boulder slag Ammonium Sulphate

19. BY PRODUCTS
• Oxygen & Nitrogen
• Coal Tar
• Granulated Blast Furnace Slag
• Refractory Bricks
• Boulder Slag
• Ammonium Sulphate

20. TAXILA
GUJRAT
WAZIRABAD
GUJRANWALA
FAISALABAD
LAHORE
KARACHI
HYDERABAD

21. PAKISTAN STEEL MILLS
…PAKISTAN STEEL is located at a distance of 40 km
South East of Karachi at Bin Qasim in close vicinity of
Port Muhammad Bin Qasim at Pipri.
It is spread over an area of 18,660 acres (about 29
square miles) including 10,390 acres for the main plant,
8070 acres for township and 200 acres for 110 MG
water reservoir. In addition it has leasehold rights over
an area of 7520 acres for the quarries of limestone and
dolomite in Makli and Jhimpir areas of district Thatta.

22. FACTORS AFFECTING LOCATION
SITE: Flat, cheap and unused land available.
NATURAL ROUTES: Port Qasim facilitates exports and
imports.
CAPITAL:USSR provided economic assistance (technology
and capital)
RAW MATERIALS: Iron ore and manganese imported through
Port Qasim. Limestone from Makli Hills near
Thatta. Water from Lake Haleji nearby.

23. ENERGY: Port Qasim and Karachi have the highest
electricity generating capacity in Pakistan.
LABOUR: Available locally from Karachi.
MARKETS: Most industries are located in Karachi. Over
half of the steel produced is used in Punjab.
TRANSPORT: Pipri is connected to main Karachi-Kotri
railway. Metalled road also connect this area to the
main road network.

24. PICTURES OF PAKISTAN STEEL MILLS

25. IMPORTANCE OF THE
I & S INDUSTRY
• ATTRACTIVE MARKET DYNAMICS DID YOU
• Captive Market KNOW?
• Growing Market PSMC with a installed capacity
of 1.1 million tonnes per annum
• COMPETITIVE POSITIONING (“mtpa”), is the country’s only
• LONG TERM RAW MATERIAL integrated steel manufacturer,
CONTRACTS accounting for approximately
• IDEAL LOCATION 23% of the country’s total
• IMPROVED FINANCIALS demand for steel in 2004.
• EXPANSION POSSIBILITY
• ENVIRONMENT, HEALTH & SAFETY
CERTIFICATION
• EXPERIENCED MANAGEMENT AND
WORKFORCE

26. EFFECTS ON THE
ENVORIMENT
• Pollution is caused by
the ships coming to
supply raw materials.
• Natural reserves of
coal, gas are being
exploited for the
raw material and
power supply.
• Fresh water is used
in the industry.

27. PROBLEMS OF THE I & S INDUSTRY
Environmental problems
A lot of pollution is caused by the iron and steel
industries. When the iron ore is burned at high
temperatures to be melted a lot of smoke is
released which in turn goes out into the
environment causing a lot of harm to it. This
also causes ozone depletion which in turn leads
to global warming.

28. Economic Problems:
Since Pakistan is not very abundant in iron ore it
has to import a lot of iron ore in order to
manufacture steel here. This causes the spending
of foreign exchange. Also a lot of iron and steel is
needed in day to day life since most of the things
are made with this raw material which could lead
to the exhaustion of resources.

29. Social Problems
Workers live and work under very poor conditions. We
see the basic violation of human rights when the
workers are made to work in extremely high
temperatures from day to night. Also they
accommodation facilities are not that good. People do
not lead quality lives. The wages are also quite low
considering the amount of work they workers do.

30. QUESTION BANK
Adapted from: O LEVEL 2059/2 PAST PAPERS 2000-2007
JUNE 2006/PAPER II/QS.4
a) Study Fig. 5, a diagram showing some inputs to Pakistan Steel.
COKING
COAL
FROM OTHER W X
COUNTRIES
PAKISTAN
STEEL Fig. 5
Y
FROM Z
COKING
PAKISTAN COAL
i) Name the two raw materials W and X. [2]
ii) Name two other inputs Y and Z. [2]
iii) Why is coal imported in addition to that produced in Pakistan? [2]

31. b) Describe how two human inputs contribute to production at Pakistan Steel? [6]
c) Why is over 50% of the output of Pakistan Steel sent north from Karachi to [3]
Punjab?
d) What features of Pakistan Steel show that it is an industry in the formal
sector? [4]
e) How does the government attract local and foreign investors to develop
industries in Pakistan? [6]
November 2005/Paper II/Qs. 4
c)
i) Give a location in Pakistan for
A the iron and steel industry
B the cement industry [2]
ii) Choose one of these industries, and state two inputs and two outputs [4]
of that industry.
***THE END***

32. PAST PAPER QUESTION FROM
2000-07
QUESTION 4:
(a) Study the diagram below showing some inputs to
Pakistan Steel.

33. i.i. Name the two raw materials w and x.
Name the two raw materials w and x.
ii. Name two inputs yy and z.
ii. Name two inputs and z.
iii. Why isiscoal imported in addition to that isis
iii. Why coal imported in addition to that
produced in Pakistan?
produced in Pakistan?
(b) Describe how two human inputs contribute to
(b) Describe how two human inputs contribute to
production at Pakistan steel?
production at Pakistan steel?
(c) Why isisover 50% of the output of Pakistan steel
(c) Why over 50% of the output of Pakistan steel
sent to north from Karachi to Punjab?
sent to north from Karachi to Punjab?
(d) What features of Pakistan steel show that itit is an
(d) What features of Pakistan steel show that is an
industry in the formal sector?
industry in the formal sector?
(e) How does the government attract the local and
(e) How does the government attract the local and
foreign investors to develop industries in
foreign investors to develop industries in
Pakistan? (June 2006)
Pakistan? (June 2006)