Steelmaking processes are the manufacturing of steel from iron ore or scrap. Pig iron is well known as the basic block of all ferrous metals, produced from refined iron ore in a blast furnace with the addition of charcoal, limestone, and air. Steel can be obtained if pig iron is further refined and some amount of carbon is added. If this is done, the crystalline structure of the metal changes and steel is then obtained. This is the most common steelmaking process ever known.
Read more:Various Methods of the steelmaking process
Today you’ll get to know the various method of steelmaking processes and how they are performed.
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Various methods of steelmaking processes
There are various methods of steelmaking, well three processes have been explained in this article.
As explained in the previous article, steel is obtained from iron that loses some of its impurities like silica, phosphorus, and sulfur. These impurities are purposely removed because it causes serious weakness to the steel. The types are;
Open-hearth furnace process
In the process of steelmaking, iron ore, pig iron, and limestone are poured through the top of the open-hearth furnace which is then heated for about 1,600°f (871°c). After the heating process, the ore and limestone form slag that is lighter than iron so it floats on the top surface. Impurities like carbon oxidized float out of the iron into the slag. After all this, carbon steel is produced.
Read more:Raw materials used in making Iron and steel
watch the video below to learn about the open-hearth furnace for the steelmaking process:
Bessemer process of Steelmaking:
The second process on how steel is produced from pig iron is the Bessemer process. This steelmaking process also involves the oxidation of impurities in the pig iron which is achieved by blow air through the molten iron in a Bessemer converter, at this point, the heat of oxidation raises the temperature and keeps the iron molten.
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Air plays an important role as it reacts with molten pig iron and makes the impurities from oxides, carbon monoxide burns off, and other impurities from slag.
Basic oxygen furnace process
A basic oxygen furnace is another process of steelmaking. Its manufacturing process is roughly 10 times faster than an open-heart furnace. This steelmaking process is achieved when high-purity oxygen blows through the molten pig iron, lowering carbon, silicon, manganese, and phosphorus levels. This sulfur and phosphorus level is reduced with the addition of a chemical cleaning agent called “fluxes.”
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The addition of alloy to the steel help in creating different properties. For example, production of stainless steel, 10 to 30% of chromium will be added to the steel. It helps the steel to highly resist rust. And for the production of chrome-moly steel, chromium, and molybdenum will be added to the steel. It is known as very strong and light steel.
Watch the video below to learn the basic oxygen furnace steelmaking process:
Read more:Heat treatment process of steel
That is all for this article, where three steelmaking process is discussed. I hope you get a lot from this post, if so, kindly share it with other students. Thanks for reading, see you next time!
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I'm a materials science enthusiast with a deep understanding of steelmaking processes. My expertise is grounded in practical knowledge and academic exploration of metallurgy. Let's delve into the concepts outlined in the article on steelmaking processes.
1. Pig Iron as the Foundation:
- Definition: Pig iron is the fundamental building block of ferrous metals.
- Production: It originates from refined iron ore in a blast furnace, incorporating charcoal, limestone, and air.
- Role: Pig iron serves as the precursor to steel.
2. Refining for Steel Production:
- Crystalline Structure Change: Further refining pig iron and adding carbon alters the metal's crystalline structure, resulting in the formation of steel.
- Key Ingredients: The refining process involves pig iron and the addition of carbon.
3. Overview of Steelmaking Processes:
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Open-hearth Furnace Process:
- Components: Iron ore, pig iron, and limestone.
- Temperature: Heated to about 1,600°F (871°C).
- Slag Formation: Ore and limestone produce slag that floats due to its lighter nature.
- Impurity Removal: Carbon oxidizes and floats into the slag, yielding carbon steel.
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Bessemer Process:
- Oxidation: Involves blowing air through molten iron in a Bessemer converter.
- Heat of Oxidation: Raises temperature, maintaining molten iron.
- Impurity Removal: Oxidation removes impurities like carbon monoxide, leading to steel production.
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Basic Oxygen Furnace Process:
- Speed: Roughly 10 times faster than an open-hearth furnace.
- Oxygen Blowing: High-purity oxygen blows through molten pig iron.
- Impurity Reduction: Carbon, silicon, manganese, and phosphorus levels decrease.
- Sulfur and Phosphorus Reduction: Chemical cleaning agent, "fluxes," is added.
4. Alloy Addition for Varied Properties:
- Stainless Steel Production: Addition of 10 to 30% chromium for rust resistance.
- Chrome-Moly Steel Production: Chromium and molybdenum addition for strength and lightness.
In summary, the steelmaking processes include open-hearth furnace, Bessemer process, and basic oxygen furnace. Each method involves distinct steps to refine pig iron, removing impurities and achieving the desired steel properties. Alloy addition further tailors steel for specific applications, such as stainless or chrome-moly steel. If you have any questions or need further details on specific aspects, feel free to ask.
