WACHEMO UNIVERSITY
College of Engineering and Technology
Department of Electro-Mechanical Engineering
Material Science and Engineering
Compiled by Dagim Asegid ([Link]. MEng.), Sept. 2023
Chapter Three
Production of Iron, Steel and
Alloy Steels
Chapter Three
3.1. Production of steel
The production of steel at an integrated iron and steel plant is accomplished using several
interrelated processes. The major operations are:
Coke production
Sinter production
Iron production
Iron preparation
Steel production
Chapter Three
3.1. Production of steel
Coke production
It is produced by destructive distillation of coal in coke ovens.
Coal is a sedimentary deposit predominantly composed of carbon.
Coal consists of more than 70% by volume carbonated materials.
Coal is heated in an oxygen free atmosphere until volatile components evaporate.
The material remaining is called Coke.
Chapter Three
3.1. Production of steel
Sinter production
The process converts fine sized raw materials in to an agglomerated products of suitable
size for charging in to the blast furnace.
The raw materials for the process include;
Iron ore
Coke breeze
Limestone
Iron oxide
Chapter Three
3.1. Production of steel
Sinter production
The raw materials are often mixed with water to provide a cohesive matrix and
then placed on the sinter strand.
Around 1300 to 1480˚C heat is used to sinter the raw materials.
The sinter products are cooled in open air.
Finally the cooled sinter is crushed and screened to charge in to blast furnace.
Chapter Three
3.1. Production of steel
Iron production
Iron is produced in blast furnaces with the reduction of iron bearing materials with
a hot gas.
Blast furnace is charged through its top with;
Iron as ore, pellets and/or sinter
Flux as limestone, dolomite
Coke as fuel
Chapter Three
3.1. Production of steel
Iron production
Iron oxides, coke and fluxes react with the blast air to form;
Reduced iron
Carbon monoxide (CO)
Slag
The molten iron and slag collect in the hearth at the base of the furnace.
Chapter Three
3.1. Production of steel
Iron preparation
The process is also known as hot metal desulfurization.
Performed in order to reduce sulfur from the molten iron before steel making
process.
The reaction forms a floating slag which can be skimmed off.
Performed in the hot metal transfer car at location between the blast furnace and
basic oxygen furnace (BOF).
Chapter Three
3.1. Production of steel
Iron preparation
The most common reagents during desulfurization include;
Powdered calcium carbide (CaC2)
Calcium carbonate (CaCO3)
Salt coted magnesium granules
The process duration may take 5 to 30 minutes depending on;
Injection rate
Hot metal chemistry
Chapter Three
3.1. Production of steel
Steel production
The production of steel can be performed in one of the following three furnaces;
Basic Oxygen Furnace (BOF)
Electric Arc Furnace (EAF)
Open Hearth Furnace (OHF)
Chapter Three
3.1. Production of steel
Steel production
Basic Oxygen Furnace (BOF)
In this process molten iron from a blast furnace and iron scrap are required in a
furnace by injecting high purity oxygen.
The input material is typically 70% molten metal and 30% scrap metal.
The reactions are exothermic, no external heat source is necessary to melt the
scrap.
Chapter Three
3.1. Production of steel
Steel production
Basic Oxygen Furnace (BOF)
Large quantities of CO is byproduct of the process.
The full furnace cycle typically ranges from 25 to 45 minute.
By far it is the fastest steel production furnace.
Chapter Three
3.1. Production of steel
Steel production
Electric Arc Furnace (EAF)
EAF is used to produce carbon and alloy steels.
The input material to an EAF is typically 100% scrap.
EAF are equipped with carbon electrodes.
Electric current of the opposite polarity electrodes generate heat between the
electrodes and through the scrap.
Chapter Three
3.1. Production of steel
Steel production
Electric Arc Furnace (EAF)
After melting and refining periods, the slag and steel are poured from the
furnace by tilting.
The production of steel in EAF is a batch process.
Cycles, or heats range from about 1-0.5 to 5hrs to produce carbon steel and
from 5 to 10 hrs or more to produce alloy steel.
Chapter Three
3.1. Production of steel
Steel production
Open Hearth Furnace (OHF)
The OHF is a shallow, refractory lined basin in which scrap and molten iron are
melted and refined in to steel.
The mixture of scrap and hot metal in OHF is half and half.
Melting heat is provide by gas burners above and at the side of the furnace.
Chapter Three
3.1. Production of steel
Steel production
Open Hearth Furnace (OHF)
Refining Is accomplished by;
The oxidation of carbon in the metal, and
The formation of a limestone slag to remove impurities.
The OHF steel making process with oxygen lancing normally requires from 4
to 10 hrs.
Chapter Three
3.2. Introduction to steel
Steel
Steels are iron–carbon alloys that may contain appreciable concentrations of other
alloying elements.
The mechanical properties are sensitive to the content of carbon, which is normally
less than 1.0 wt.%
Chapter Three
3.2. Introduction to steel
i. Steel
Some of the more common steels are classified according to carbon concentration namely;
Low-carbon steel,
Medium-carbon steel, and
High-carbon steel
Chapter Three
3.3. Classification of carbon steel
i. Steel
Subclasses also exist within each group according to the concentration of other alloying
elements.
Plain carbon steels contain only residual concentrations of impurities other
than carbon and a little manganese.
For alloy steels, more alloying elements are intentionally added in specific
concentrations.
Chapter Three
3.3. Classification of carbon steel
Steel
Chapter Three
3.3. Classification of carbon steel
Steel
a) Low carbon steel
Contain less than 0.25 wt.% of C.
Strengthened by cold work.
Consist ferrite and perlite microstructure
Relatively soft and weak
Chapter Three
3.3. Classification of carbon steel
Steel
a) Low carbon steel
Outstanding ductility and toughness
Machinable and weldable
Least expensive to produce
Chapter Three
3.3. Classification of carbon steel
Steel
a) Low carbon steel
Application ;
Automobile body components
Structural shapes (I beams, channels and angle iron)
Sheets for pipes, buildings and tin cans, nut and bolt.
Chapter Three
3.3. Classification of carbon steel
Steel
b) Medium carbon steel
Contain carbon between 0.25 wt.% and 0.60 wt.%
Strengthened by heat treatment
Utilized in tempered condition
Addition of Cr, Ni, and Mo improve the heat treatment capacity
Stronger than low carbon steel at a sacrifice of ductility and toughness
Chapter Three
3.3. Classification of carbon steel
Steel
b) Medium carbon steel
Application;
Railways wheels and tracks
Gears, crank shafts
Structural components for a combination of strength and wear
resistance
Chapter Three
3.3. Classification of carbon steel
Steel
c) High carbon steel
Carbon content between 0.60 and 1.4 wt.%
Hardest, strongest and yet least ductile of the carbon steels.
Strengthen by heat treatment.
Used in hardened and tempered conditions
Especially wear resistant and capable of holding a sharp cutting edge.
Chapter Three
3.3. Classification of carbon steel
Steel
c) High carbon steel
Application;
Tool and die steels
Sharp cutting tools such as:
Knives, razors, and
Hack saw blades
Chapter Three
3.4. Effects of alloying elements
Chapter Three
3.4. Effects of alloying elements
Chapter Three
3.4. Effects of alloying elements
Steel
Effects of increasing carbon content in steel are;
Increase in hardness and strength
Decrease in weldability
Decrease in ductility
Decreased machinability
Chapter Three
3.5. Classification of alloy steel
Steel
Stainless steels
Highly resistant to corrosion (rusting)
Cr < 11 wt.% is a predominant alloying element
Addition of Mo and Ni enhance corrosion resistance
Chapter Three
3.5. Classification of alloy steel
Steel
Stainless steels
Based on predominant phase constituent of the microstructure they can be
classified as;
Martensitic stainless steel
Ferritic stainless steel
Austenitic stainless steel
Chapter Three
3.5. Classification of alloy steel
Steel
a) Martensitic stainless steel
Capable of being heat treated
Martensite is there primary phase constituent
Have magnetic properties
Chapter Three
3.5. Classification of alloy steel
Steel
b) Ferritic stainless steel
Not heat treatable
Hardened and strengthen by cold working
Have magnetic properties
Chapter Three
3.5. Classification of alloy steel
Steel
c) Austenitic stainless steel
Not heat treatable
Hardened and strengthen by cold working
The most corrosion resistance due to high content of Ni and Cr
Produced in the largest quantities
They are not magnetic
Chapter One
End Of Chapter Three
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