When we turn to the minerals used for making the alloys of iron and as accessories in the manufacture of iron, it appears that no one of the principal iron and steel producing countries of the world is self-supporting, but that these "sweeteners" must be drawn in from the far corners of the earth. The importance of these minor constituents is altogether out of proportion to their volume. For instance, only fourteen pounds of manganese are necessary in the making of a ton of steel, yet a ton of steel cannot be made without manganese. The increasing specialization in iron and steel products, and the rapidly widening knowledge of the qualities of the different alloys, are constantly shifting the demand from one to the other of the ferro-alloy minerals. Each one of the ferro-alloy minerals may be regarded as being in the nature of a key mineral for the iron and steel industry, and the control of deposits of these minerals is a matter of international concern. Control is not a difficult matter, in view of the fact that the principal supplies of practically every one of the alloy minerals are concentrated in comparatively few spots on the globe,—as indicated on succeeding pages.
Nature has not endowed the United States, nor in fact the North American continent, with adequate high-grade supplies of the principal ferro-alloy minerals,—with the exception of molybdenum, and with the exception of silica, magnesite, and fluorspar, which are used as accessories in the process of steel making. With plenty of iron ore and coal, and with an iron and steel capacity amounting to over 50 per cent of the world's total, the United States is very largely dependent on other countries for its supplies of the ferro-alloy minerals. The war brought this fact home. With the closing of foreign sources of supplies, it looked at one time as if our steel industry was to be very greatly hampered; and extraordinary efforts were made to keep channels of importation open until something could be done in the way of development, even at excessive cost, of domestic supplies. The result of war efforts was a very large development of domestic supplies of practically all the ferro-alloy minerals; but in no case, with the exceptions noted above, did these prove sufficient to meet the total requirements. This development was at great cost and at some sacrifice to metallurgical efficiency, due to the low and variable grades of the raw materials. With the post-war reopening of importation much of the domestic production has necessarily ceased, and large amounts of money patriotically spent in the effort to meet the domestic requirements have been lost. These circumstances have resulted in the demand in Congress from producers for direct financial relief and in demand for protective tariffs, in order to enable the new struggling industries to exist, and to permit of development of adequate home supplies. Such tariffs might be beneficial to these particular domestic industries if wisely planned; but also, in view of the limited amounts of these particular ores in this country, their general low grade, and the high cost of mining, tariffs might very probably hasten exhaustion of our limited supplies and might handicap our metallurgical industries both in efficiency and cost (see pp. 365-366, 393-394).
IRON ORES
Economic Features
Technical and commercial factors determining use of iron ore minerals. Popularly, an iron ore is an iron ore, and there is little realization of its really great complexity of composition and the difficulty of determining what is or is not a commercial ore. Percentage of iron is of course an important factor; but an ore in which the iron is in the mineral hematite is more valuable than one with an equivalent percentage of iron which is in the form of magnetite. Substances present in the ore in minor quantities, such as phosphorus, sulphur, and titanium, have a tendency to make the iron product brittle, either when it is cold or when it is being made, so that excessive amounts of these substances may disqualify an ore. Excessive quantities of silica, lime, or magnesia may make the ore undesirable. Where an acid substance, like silica, is balanced by basic constituents like lime and magnesia, considerable amounts of both may be used. Excessive moisture content may spoil an ore because of the amount of heat necessary to eliminate it in smelting.
The metallurgical processes of the iron and steel industry are essentially adapted to the principal grades of ore available. The cheapest of the steel-making processes, called the acid Bessemer process, requires a very low-phosphorus ore (usually below .050 per cent in the United States and below .030 per cent in England.) The basic open-hearth processes, making two-thirds of the steel in the United States, allow higher percentages of phosphorus, but not unlimited amounts. The basic Bessemer (Thomas) process, used for the "minette" ores of western Europe and the Swedish magnetites, may use an ore with any amount of phosphorus over 1.5 per cent. The phosphatic slag from this process is used as fertilizer. The supply of low-phosphorus Bessemer ore in the United States is at present limited as compared with that of the non-Bessemer ores, with the result that steel-plant construction for many years past has been largely open-hearth. The open-hearth process is favored also because it allows closer control of phosphorus content in the steel.
Small but increasing amounts of steel are also made in the electric furnace; for the most part, however, this process is more expensive than the others, and it is used principally for special alloy steels.
Iron ores are seldom so uniform in quality that they can be shipped without careful attention to sampling and grade. In the Lake Superior region the ores are sampled daily as mined, and the utmost care is taken to mix and load the ore in such a way that the desired grades can be obtained. Ordinarily a single deposit produces several grades of ore. When ores are put into the furnace for smelting the mixtures are selected with great care for the particular purpose for which the product is to be used. The mixture is compounded as carefully as a druggist's prescription. An ore salesman, after ascertaining the nature of the iron and steel products of a plant, has to use great skill in offering particular ores for sale which not only will meet the desired grade in regard to all elements, but also will meet competition in price. In some respects, the marketing of different grades of iron ore is as complex as the marketing of a miscellaneous stock of merchandise. With ores, as with merchandise, custom and sentiment play their part,—with the result that two ores of identical grade mineralogically and chemically may have quite a different vogue and price, simply because of the fact that furnace men are used to one and not to the other and are not willing to experiment.
The geologist is ordinarily concerned merely with finding an ore of as good a general grade as possible; but he often finds to his surprise that his efforts have been directed toward the discovery of something which, due to some minor defect in texture, in mineralogical composition, or in chemical composition, is difficult to introduce on the market. There is here a promising field, intermediate between geology (or mineralogy) and metallurgy, for the application of principles of chemistry, metallurgy, and mineralogy, which is occupied at the present time mainly by the ore salesman. Both the mineralogist and metallurgist touch the problem but they do not cover it. With increasingly precise and rapidly changing metallurgical requirements, this field calls for scientific development.
Geographic distribution of iron ore production. Iron ores are widely distributed over the world, but are produced and smelted on a large scale only in a few places where there is a fortunate conjunction of high grades, large quantity, proximity of coal, cheap transportation to markets, and manufacturing enterprise. Over 90 per cent of the iron ore production of the world is in countries bordering the North Atlantic basin. The United States produces about 40 per cent, France about 12 per cent, England about 10 per cent, Germany before the war 15 to 20 per cent, and Spain, Russia, and Sweden each about 5 per cent. Lesser producing countries are Luxemburg, Austria-Hungary, Cuba, Newfoundland, and Algeria; and insignificant amounts are produced in many other parts of the world. Of the world's iron and steel manufacturing capacity, the United States has about 53 per cent, Germany 16 per cent, England 14 per cent, France 10 per cent, the remainder of Europe (chiefly Russia, Austria-Hungary, and Belgium) 7 per cent. The absence of important iron ore production and of iron and steel manufacture either in the southern hemisphere or in any of the countries bordering the Pacific is a significant feature, when we remember what part iron plays in modern civilization. Japan, however, is beginning to develop a considerable iron and steel industry, which promises to use a large amount of ore from China, Manchuria, and Korea, and possibly to compete in American Pacific Coast markets.