Steel Making Introduction

 STEEL is an alloy –From Iron and Carbon.

 In general less than 2% Carbon.
 Other elements present such as Mn, Si, S, P
by their association in the process of iron
and steelmaking.
 Alloying additions are done to improve
better mechanical strength, ductility,
electrical and magnetic properties,
corrosion resistance
 Developed by Henry Bessemer in 1856 in
Sheffield in England.
 Steel – 1) Plain carbon steel 2) alloy steel
 Plain carbon steels are divided as below :

Class % Carbon
low carbon steels up to 0·15% C
Mild steels 0·15-0·35% C
Medium carbon steels 0·35-0·65% C
High carbon steels 0·65-1·75% C
 Alloy steels are divided as below :

Class % Alloying addition

Low alloy steels up to 5% total alloying
contents
Medium alloy steels 5-10% total alloying
High alloy steels above 10% total alloying
 1
• Blast Furnace

2
• Basic Oxygen furnace

3
• Ladle Treatment

4
• Continuous Casting

5
• Rolling

6
• Flat or Long products

Adopted by Integrated Steel Plants

(Route 1)
 • Blast Furnace
1

• Electric Arc Furnace

2

• Ladle Treatment
3

• Continuous Casting
4

• Rolling
5

• Mostly Long products but occasionally flat products.

6

Adopted by Mini Steel Plants (Route 2)

Alloy and special steels are produced by route 2. Some plants employ
Argon‐Oxygen‐decarburization process instead of Electric Arc Furnace
 Steel is Different From Wrought and Cast Iron

Wrought Iron

 Almost pure of iron (<0.02-0.05%C)

 Consist Siliceous slag (Fe2SiO4)
 Easily shaped, forged
 Soft, doesn’t harden similarly like steel
 Used in gates, fences, railings, grilles.
 Either Riveted or heat welded

Cast Iron

 High C content (>2 %C) as compared to steel, Silicon : 1-3%

 Easily castable
 Very hard and brittle, difficult in machining
 Used in oil and gas industry as boilers, valves and in water pipeline
 Depending on the morphology of graphite cast iron can be gray, white, malleable,
ductile types
Different Processess

Bessemer Process

Open Hearth Process

Basic Oxygen Furnace

Electric Arc Furnace

Rotating Steel Making (Kaldo, Rotor)

Q-BOP Process

Combined blowing process

Modified Conventional process

Different Processes
 Steel Plant PROCESS FLOW

Iron making Steel making Continuous casting Rolling Main products

Rail
Integrated Sheet pile
Open DCS
Shape
Pellet Coke Section mill Bar

Wire rod
Iron ore Sintered Limestone
ore Wire rod mill

Plate
Hot
direct Plate mill
Billet rolling
Hot metal Hot rolled coil
(HDR)
and sheet
Hot strip mill
Basic oxygen furnace
(BOF) Bloom
Cold rolled coil
and sheet
(also for plating)
Slab Cold rolling tandem mill
Blast furnace
(BF) Welded pipe
Butt welded pipe
Welded pipe mill
Scrap Electric arc furnace
(EAF) Seamless pip
Seamless pipe mill
Reheating furnace
Field Instrument Steel casting
& Control Valves
 Steel Making scenario (Production in
World)
Year Million tonnes, Year Million tonnes,
crude steel production crude steel production
2000 850 2010 1433
2001 852 2011 1538
2002 905 2012 1560
2003 971 2013 1650
2004 1063 2014 1669
2005 1148 2015 1620
2006 1250 2016 1627
2007 1348 2017 1730
2008 1343 2018 1808
2009 1239
Source : World Steel Association
WORLD STEEL IN FIGURES 2019
 Steel Making scenario (Production
Country wise, 2018)
Country Million tonnes,
crude steel production
China 928.8
India 106.5
Japan 104.3
United States 86.6
South Korea 72.5
Russia 71.7
Germany 42.4
Turkey 37.2
Brazil 34.9
Italy 24.5
Source : World Steel Association
WORLD STEEL IN FIGURES 2019
Steel Making scenario
TOP STEELMAKERS, (2018)
Country
ArcelorMittal
China Baowu Group
Nippon Steel Corporation (Japan)
HBIS Group (Hesteel Group)
POSCO (South Korea)
Shagang Group (China)
Ansteel Group (China)
JFE Steel Corporation (Japan)
Jianlong Group (Beijing)
Shougang Group (Beijing)
Tata Steel Group (India)
Source : World Steel Association
WORLD STEEL IN FIGURES 2019
 Steel Making scenario
Contribution of different process in Indian Steel making in 2018

Process Contribution (%)

Oxygen steelmaking 46.7
Electric Furnace steelmaking 53.3

In some countries open hearth steel making process is still operative

Such as :
 Ukraine
 Russia

However considering the world Oxygen steelmaking is the major contributor

(around 71%), followed by electric arc furnace and the contribution of open hearth
steel making is <1%.
Source : World Steel Association
WORLD STEEL IN FIGURES 2019
Steel Making scenario
Million Tonnes Export and Import in 2018
Total Exports Total Imports
China European Union
Japan United States
Russia Germany
South Korea Italy
European Union Thailand
Germany South Korea
Turkey France
Italy Belgium
Belgium China
Ukraine Vietnam

Source : World Steel Association

WORLD STEEL IN FIGURES 2019