Process of Steel Manufacturing
Process of Steel Manufacturing
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Steel is one of the most preferred materials for construction, manufacturing of tools, cars, and for various other applications. It is an alloy of iron and some other elements such as chromium.
Steel has been manufactured for ages, but the large-scale commercialization of the process began only in the 19th century. The 1850s and 1860s saw the advent of different revolutionary techniques, which turned the steel-making process into a mainstream industry.
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Manufacturing
Ancient steel manufacturing process was carried out in bloomeries and crucibles. The Industrial Revolution brought about the development of large scale methods of producing steel.
Modern steel industries use recycled materials as well as traditional raw materials such as iron ore, coal and limestone. Almost all the steel manufactured today uses 2 processes-basic oxygen steelmaking (BOS) and electric arc furnaces (EAF).
There are 6 basic steps in the Steel-making processes, which are as follows-
1. Iron-making
This is the first step in the manufacturing of pure steel. In this step, the raw materials like iron ore, coal and lime are melted in a blast furnace. This results in the formation of molten iron, also known as hot metal, which still contains 4-4.5% of carbon and other impurities, which makes it brittle. These have to be subsequently removed.
2. Primary Steel Making
The remaining impurities are removed by either BOS or EAF methods.
Oxygen is blown through the metal at high temperatures and this reduces the carbon content to about 0-1.5%.
The final grade of steel that is desired determines the further techniques that need to be applied. These may include-
- Stirring
- Altering the temperature
- Ladle injection
- Removal of gasses
- CAS-OB
- Continuous Casting
In this step, the molten steel is cast into cooled moulds, causing the steel to harden. Next, it is cut to the desired lengths, depending on the applications-beams, slabs, billets, etc.
3. Primary Forging
In primary forming, the cut steel is formed into different shapes, generally by hot rolling, which eliminates the casting defects and gives a desirable shape and surface quality. Seamless tubing, long products, flat products and various other speciality products can be obtained by this process.
4. Secondary Forming
The final step is the secondary forming process, which gives the steel its finished shape and properties. Various techniques can be applied at this stage, which involve-
- Heat treatment (tempering)
- Joining (welding)
- Shaping (cold rolling)
- Coating (galvanising)
- Machining (drilling)
- Surface treatment (carburising)
JSW Steel of India and Marubeni-Itochu Steel of Japan have collaborated to create JSW MI.
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