GFG Foundation Student Programme
YEAR 2
Blast Furnace
You will learn about blast furnaces and how they are being replaced with modern electric arc furnaces to combat climate change.
In pairs, you will use STEM (Science, Technology, Engineering, and Maths) skills to construct a model blast furnace from wooden and electrical components. Compete in a game to make all LED lights within the model’s chimney glow red.
The player within each pair who has the fewest attempts will win, but also the pair with the fewest combined attempts will win the overall trophy.
Student Workbook
Wiring Instructions
Building Instructions
Blast Furnace Game
Game description and rules
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Take it in turns in pressing and holding the button on your model blast furnace.
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Holding the button activates the lights within the chimney.
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The lights loop from yellow through orange and red before starting again at yellow.
The aim of the game is for you to release the button when all of the lights are red.
Your teammate logs your number of attempts on the scorecard below. Teammates
take turns to play and score.
Like a penalty shootout in football, each teammate plays 5 times with the person
achieving all red lights in fewer attempts in
Or use the form below for temporary notes
Retrofit Steel Plant
You will learn about blast furnaces and how they are being replaced with modern electric arc furnaces to combat climate change.In pairs, you will use STEM (Science, Technology, Engineering, and Maths) skills to construct a model blast furnace from wooden and electrical components. Compete in a game to make all LED lights within the model’s chimney glow red.The player within each pair who has the fewest attempts will win, but also the pair with the fewest combined attempts will win the overall trophy.
Student Workbook
Raw Materials/ Scrap Yard
The Raw Materials household consists of stacks/ piles of iron ore, coke, coal etc. which are then used in the steel producing process. The raw materials are operated with horizontal excavators and transported to the end of use with the help of conveyor belts.
The Scrap Yard is a platform where pieces of scrap steel are collected, sorted by size and characteristics, and loaded into wagons or trucks to be sent to the Steel Works for melting. The scrap metal is operated with the help of cranes with tongs or powerful magnets.
Jobs
Pile-up Preparatory
The pile-up preparatory worker carries out maintenance and remedial activities according to the specific instructions carried out for the transport of raw materials, spill elements and conveyors within the sector.
He is responsible for checking the technical condition of the equipment after the repair work, and after taking all the safety measures, he puts it into working condition.
Electrician
An electrician is that person responsible for the design, installation, maintenance and repair of residential, commercial, industrial electrical systems and electrical appliances or those used in public spaces.
He is a professional trained to work with electrical installations right from the initial phase, that of assembly, but he also deals with the maintenance operations related to normal use.
Electrical Engineer
The electrical engineer works on the design, protection and control of electrical energy production, transmission, and distribution systems. Performs necessary calculations and quality controls in the production of electrical power generating equipment, vehicles and other equipment used in electrical power distribution.
Also performs repair activities for electrical circuits, installations, diagnoses, and fixes defects found in electrical installations.
Blast Furnace/ Electric Arc Furnace
A blast furnace is a type of metallurgical furnace used for smelting to produce hot metal. In a blast furnace, fuel (coke), ores, and flux (limestone) are continuously supplied through the top of the furnace, while a hot blast of air is blown into the lower section of the furnace through a series of pipes so that the chemical reactions take place throughout the furnace as the material falls downward. The end products are hot metal and slag phases tapped from the bottom, and waste gases from the top of the furnace
An electric arc furnace is a furnace that heats the steel by means of an electric arc. In electric arc furnaces, the charged material (the scrap, basically) is directly exposed to an electric arc, and the current from the electrode terminals passes through the charged material.
Jobs
Planning engineer
Planning engineers help engineering teams deliver projects on schedule.
They develop strategies, determine material and labor costs, monitor crew performance, ensure health and safety regulations are obeyed, and that communications channels are open. Planning engineer also interpret data, compile reports, and deliver presentations when required.
They demonstrates a sound knowledge of the relevant Engineering discipline and be able to anticipate problems.
Planning engineers have also a great attention to detail and is able to handle stress well.
Electrical Engineer
The electrical engineer works on the design, protection and control of electrical energy production, transmission, and distribution systems. Performs necessary calculations and quality controls in the production of electrical power generating equipment, vehicles and other equipment used in electrical power distribution.
Also performs repair activities for electrical circuits, installations, diagnoses, and fixes defects found in electrical installations.
Blast furnace operator
A blast furnace operator is a professional responsible for ensuring the safe and efficient operation of industrial equipment. They handle hazardous chemicals, operate computer systems, and respond to potentially hazardous situations.
They also comply with safety regulations and handle heavy lifting tasks. They record data such as temperature, pressure, water levels, fuel consumption, and other relevant information in logbooks. Their job often involves working with hazardous materials, and they must follow all relevant guidelines to ensure safety.
Electrician
An electrician is that person responsible for the design, installation, maintenance and repair of residential, commercial, industrial electrical systems and electrical appliances or those used in public spaces.
He is a professional trained to work with electrical installations right from the initial phase, that of assembly, but he also deals with the maintenance operations related to normal use.
Power Plant & Green Energy Production Plant
The power distribution plant collects the electricity produced by both the Sun and the wind and distributes it to the Electric Arc Furnace, rolling mills and other users. This function also receives and distributes the energy brought from the national electricity grid and ensures the balancing of the consumption of different types of electricity.
In the new green energy production capacity, electricity is obtained directly from the Sun, through photo-voltaic panels or from the wind, with the help of wind turbines. Thus, the energy produced does not have a carbon footprint, as is the case with electricity obtained by burning fossil fuels.
Jobs
Electrician
An electrician is that person responsible for the design, installation, maintenance and repair of residential, commercial, industrial electrical systems and electrical appliances or those used in public spaces.
He is a professional trained to work with electrical installations right from the initial phase, that of assembly, but he also deals with the maintenance operations related to normal use.
Electrical Engineer
The electrical engineer works on the design, protection and control of electrical energy production, transmission, and distribution systems. Performs necessary calculations and quality controls in the production of electrical power generating equipment, vehicles and other equipment used in electrical power distribution.
Also performs repair activities for electrical circuits, installations, diagnoses, and fixes defects found in electrical installations.
Steel Shop (with Converter)
A classic Steel Shop, with converter(s)” is using the method of primary steelmaking in which carbon-rich hot metal is made into steel. Blowing oxygen through liquid hot metal lowers the carbon content of the alloy and changes it into low-carbon steel.
The process is known as basic because fluxes of burnt lime or dolomite, which are chemical bases, are added to promote the removal of the impurities and protecting the lining of the converter.
Jobs
Steelworker
Steelworker position is a position within a steel plant, where workers are responsible for operations related to steel production. This job involves monitoring and controlling the smelting processes of iron ore and other materials to obtain the desired steel.
Workers in this position can operate large and complex equipment such as converters and must comply with strict safety and quality standards to ensure efficient and high-quality steel production
Electrical Engineer
The electrical engineer works on the design, protection and control of electrical energy production, transmission, and distribution systems. Performs necessary calculations and quality controls in the production of electrical power generating equipment, vehicles and other equipment used in electrical power distribution.
Also performs repair activities for electrical circuits, installations, diagnoses, and fixes defects found in electrical installations.
Electrician
An electrician is that person responsible for the design, installation, maintenance and repair of residential, commercial, industrial electrical systems and electrical appliances or those used in public spaces.
He is a professional trained to work with electrical installations right from the initial phase, that of assembly, but he also deals with the maintenance operations related to normal use.
Continuous Casting
In Continuous Casting, liquid steel is poured into a tank from which the liquid then descends into a quarter-circle shaped tube. As it descends, the steel cools and solidifies. On exiting the tube, the steel is cut into long, parallelepiped-shaped pieces, named slabs, which are cooled, stored, and become raw material for rolling mills.
Jobs
Electrical Engineer
The electrical engineer works on the design, protection and control of electrical energy production, transmission, and distribution systems. Performs necessary calculations and quality controls in the production of electrical power generating equipment, vehicles and other equipment used in electrical power distribution.
Also performs repair activities for electrical circuits, installations, diagnoses, and fixes defects found in electrical installations.
Electrician
An electrician is that person responsible for the design, installation, maintenance and repair of residential, commercial, industrial electrical systems and electrical appliances or those used in public spaces.
He is a professional trained to work with electrical installations right from the initial phase, that of assembly, but he also deals with the maintenance operations related to normal use.
Preparatory Caster
The position of Caster preparatory is essential in the industrial manufacturing process, in steel industry. The main responsibility of a preparatory foundry is related to casting machines. This includes preparing them to ensure efficient and quality production.
The caster preparatory must also monitor and maintain the equipment and machines used in the process, in good working order, and ensure compliance with safety and quality standards. A good preparatory foundry must pay attention to detail, have mechanical skills and be able to work in an environment where strict safety rules and work procedures are followed
Rolling Mill/ Finishing
Rolling mills are production lines where slabs are heated and passed through several rolling cylinders. As a result of these passes, the steel thins and elongates. At the end of the line, the steel strip is cut into sheets or rolled into cylinders, according to customers' requests. Rolled steel can be coated with zinc or paint.
Jobs
Process Engineer
A process engineer optimizes and improves the efficiency of an organization’s manufacturing and industrial processes. They ensure the smooth functioning of production lines, develop new techniques, modify existing designs, and coordinate process improvement projects.
The primary responsibilities of process engineers include analyzing existing processes, identifying areas for improvement, and implementing solutions to enhance operational performance.
These professionals work closely with cross-functional teams to evaluate workflows, identify bottlenecks, and propose innovative solutions to improve productivity and quality.
They also implement lean manufacturing principles, conduct process audits, and develop standard operating procedures.
Pickle worker
The pickle worker is the person who feeds the Pickling line based on the manufacturing program, who ensures and verifies the correct implementation of the adjustments on the sections, in the pickling process.
He is also responsible for inspecting the rolls fed into the line, prepares them, and checks their traceability.
Automation Engineer
Automation engineers are experts who have the knowledge and ability to design, create, develop, and manage machines and systems, for example, factory automation, process automation and warehouse automation.
The goal of an automation engineer is to eliminate defects, errors, and problems with product or software development and with business or customer service processes.
Support/ Office
The Human Resources function ensures the relationship between employees and the company. Employees can obtain specific services, documents, information, request training and professional development courses, discuss their career path and obtain data about available jobs.
Jobs
Human Resources Inspector
The position of human resource inspector involves monitoring and implementing HR policies and procedures in an organization. The responsibilities of an HR inspector include staff recruitment and selection, managing employee files, ensuring compliance with human resources legislation and regulations, facilitating communication between employees and management.
The Human Resources Inspector may also be involved in, managing labor disputes and providing assistance in the field of labor relations. An effective HR inspector must be familiar with HR legislation and policies, have excellent communication and interpersonal relationship skills, pay attention to detail and be able to work effectively in a dynamic and ever-changing environment.
Accountant
The post of accountant involves the correct management and recording of financial transactions of a company or organization. The responsibilities of an accountant include preparing and analyzing financial reports, such as balance sheets, profit and loss accounts, and cash flow reports.
The accountant must also ensure that all transactions comply with the tax and accounting regulations in force.
Other responsibilities may include preparing tax returns, managing payments to suppliers and collecting from customers, as well as consulting with management for financial planning and strategic decision making. An effective accountant must be accurate, organized, and have solid knowledge of accounting and tax law.
Health and Safety Inspector/ Specialist
The position of health and safety inspector involves ensuring safe and healthy working conditions for employees in an organization. Responsibilities include identifying and assessing occupational safety and health risks, developing and implementing prevention and protection measures, training and informing employees about safety rules and procedures, and investigating incidents and accidents at work.
Also, must monitor compliance with occupational safety and health regulations and standards, collaborate with other departments to identify and implement improved solutions and provide advice and support on issues related to occupational safety and health. An effective health and safety inspector must have a solid knowledge of occupational safety and health, be able to identify and assess risks, have excellent communication skills and be able to work effectively in a dynamic and interdisciplinary environment.
Buyer
The post of buyer implies responsibility for purchasing goods and services necessary for the operations of a company or organization. The buyer is responsible for identifying potential suppliers, negotiating contracts, evaluating bids and making procurement decisions in accordance with the company's requirements and budget.
He must also monitor stocks, manage relationships with suppliers and ensure prompt and efficient delivery of purchased goods or services. An effective buyer must be result-oriented, have excellent negotiation and communication skills, be organized and have solid knowledge of procurement and logistics. It is also important to have the ability to work under pressure and be able to make quick and rational decisions.
Auditor
The job of auditor involves the accurate examination and evaluation of the financial status, processes and procedures of a company or organization.
The auditor's role is to verify the financial records to ensure that they are accurate, complete, and compliant with applicable accounting and tax regulations. The auditor also investigates the company's internal control system to identify potential risks or deficiencies and recommend improvements.
The auditor can also perform performance and efficiency reviews to help optimize operations and make strategic decisions. A successful auditor must have a solid knowledge of accounting and auditing, pay attention to detail, and have excellent analytical and communication skills. It is also essential that they comply with high ethical and professional standards in the exercise of audit work.
Seed Bombs (Liberty Club)
Rewise Learning has teamed up with The Wates Group to devise a unique new educational outreach project focusing on developing STEM skills in young people and using STEM subjects to solve critical environmental problems such as climate change, global warming, maintaining biodiversity, and achieving NET zero emissions.
Wates Construction is a UK-wide contractor working with partners in both public and private sectors to create a more sustainable built environment and deliver lasting legacies for the communities in which they work. They employ 3,800 people and work with a wide range of public and private sector customers and partners. As the leaders in their field, they are working to eliminate carbon from their operations by 2025 and are committed to being a truly inclusive employer.
