MANUFACTURING &

INDUSTRIAL PROCESSES
WITH PLANT VISIT
Engr. Peter Clyde B. Lamadrid
METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
INTRODUCTION
In early times when coal was consumed in far greater proportions
in steel production, the trend was to site integrated plants either near
the coal source, or near low-grade, but cheap ore. However, with the
improvements in bulk transport and the relatively greater cost of
handling finished products, the trend is towards locating integrated
plants on deep water ports, perhaps thousands of kilometers from ore
and/ or coal but close to markets and services. They may supply semi-
finished products to more specialized finishing mills still closer to the
market. The other major steelmaking method involves the melting and
refining of steel scrap in an Electric Arc Furnace. Pig iron and refined
iron ore pellets (briquetted iron) can also be used, and because this
method is economic at lower volumes these operations are called mini
mills. Plants that use Electric Arc Furnaces can be sited closer to the
market.
METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING

 CLASSIFICATIONS OF METAL ALLOYS:

METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING

Ferrous alloys
- Iron is the prime constituent
- Steel is an iron-based alloy containing typically less than 1%
carbon, where iron frequently contains 2% or more carbon.
- Cast iron is a group of iron-carbon alloys with a carbon content
more than 2%. Its usefulness derives from its relatively low melting
temperature.
- Ferrous metal materials are carbon, alloy, stainless, tool and die
steels
- Non-ferrous metal materials are aluminum, magnesium, copper,
nickel, titanium, superalloys, refractory metals, beryllium, zirconium,
low-melting alloys, gold, silver, platinum
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 RAW MATERIALS
The basic raw materials of large-
scale steelmaking are:
1. Iron ore – it is treated in
some way after it comes
from the mine
2. Coal – must converted to
coke ( is a grey, hard, https://en.wikipedia.org/wiki/Iron_ore
and porous fuel with a
high carbon content and
few impurities, made by
heating coal or oil in the
absence of air—
a destructive
distillation process)
https://www.pinterest.ph/pin/568368415444355389/
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 RAW MATERIALS
The basic raw materials of large-
scale steelmaking are:
3. Limestone - is a common type
of carbonate sedimentary
rock.
https://en.wikipedia.org/wi https://www.sandat
4. Steel scrap - important both to ki/Limestone las.org/limestone/
the integrated steelworks as
secondary feed to the
steelmaking furnace, and to
the smaller scale "mini-mill"
operator and special

https://www.recyclingtoday.com/article/phillipines-
china-nickel-ore-stainless-steel-recycling/
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 RAW MATERIALS
The basic raw materials of large-
scale steelmaking are:
3. Steel Producer
4. Fluxing materials
5. Refractory materials - are
inorganic non-metallic material
which can withstand high
temperature without
undergoing physio – chemical
changes while remaining in
contact with molten slag, metal
and gases. They are exposed to
environments above 1,000 °F
(811 K; 538 °C)" https://sciexaminer.com/news/refractories-market-
insights-global-outlook-2019-2026-10172.html
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 RAW MATERIALS
The basic raw materials of large-
scale steelmaking are:
3. Alloys - which are elements
added to steel to give it
special properties for a variety
of uses.

https://www.thoughtco.com/metal-alloys-2340254
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 STEEL MAKING PROCESS AND EQUIPMENT
Integrated steelmaking operations fall into
three main phases:
1. Reduction: lron making
Iron ore, as mined, is a combination of
iron with oxygen and various other
unwanted substances, generally known as
"gangue". The first metallurgical step is to
reduce iron ore to metallic iron, a process
which is mostly carried out in a blast
furnace, using coke as both a fuel and
reducing agent. The metallic iron
produced by such a furnace contains a
relatively high proportion of carbon (4%)
and is passed to the steelmaking process https://www.thermofisher.com/blog/materials/the-
as a liquid at approximately 1450C, called importance-of-metallurgical-slags-and-their-
"hot metal". evaluation/
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 STEEL MAKING PROCESS AND EQUIPMENT
Integrated steelmaking operations fall into
three main phases:
2. Refining : Steel making
The refining of iron to make steel is
where the carbon content of hot metal is
lowered, usually to less than 1 % by an
oxidation process in a steelmaking furnace.
At the same time, alloying materials are
added to the furnace to achieve the
required chemical composition of the final
product. Originally most steel was
produced by the "Bessemer" and "open
hearth" processes but these have been
replaced by the more modern "basic https://www.researchgate.net/figure/Schematic-
oxygen steelmaking" (BOS) and "electric representation-of-the-basic-oxygen-furnace-process-
arc furnace" (EAF) processes. 1-4_fig8_258379527
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 STEEL MAKING PROCESS AND EQUIPMENT
Integrated steelmaking operations fall into
three main phases:
2. Refining : Steel making
The refining of iron to make steel is
where the carbon content of hot metal is
lowered, usually to less than 1 % by an
oxidation process in a steelmaking furnace.
At the same time, alloying materials are
added to the furnace to achieve the
required chemical composition of the final
product. Originally most steel was
produced by the "Bessemer" and "open
hearth" processes but these have been https://www.researchgate.net/figure/Illustration-of-
replaced by the more modern "basic electric-arc-furnace_fig1_303795438
oxygen steelmaking" (BOS) and "electric
arc furnace" (EAF) processes.
METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING

 STEEL MAKING PROCESS AND EQUIPMENT

Integrated steelmaking operations fall into three main phases:
2. Refining : Steel making
The BOS process uses pure oxygen, injected by a lance, for
refining the relatively impure hot metal (and scrap is used for
temperature control).
The electric arc furnace uses primarily electrical energy to
supply heat to melt scrap steel, sponge iron, or mixtures of
scrap and other iron units. Compared to the BOS process, the
EAF requires less chemical reaction for refining.
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 STEEL MAKING PROCESS AND EQUIPMENT
Integrated steelmaking operations fall into
three main phases:
3. Shaping and Coating
The liquid steel can then be cast or
formed into a variety of solid shapes via the
'continuous casting' process. The cast steel
can then be forged or rolled in successive
steps to produce anyone of the many
required shapes. Rolling is the most common
method of shaping.
Once shaped, steel may be coated with
other metals such as zinc or tin, or with https://www.researchgate.net/figure/Schematic-
organic coatings like paint or PVC. description-of-the-continuous-casting-process-of-
steel_fig1_322546316
 METHODS, PROCESSES, AND EQUIPMENT
FOR STEEL MANUFACTURING
 STEEL MAKING PROCESSAND EQUIPMENT
Integrated steelmaking operations fall into
three main phases:
3. Shaping and Coating
The liquid steel can then be cast or
formed into a variety of solid shapes via the
'continuous casting' process. The cast steel
can then be forged or rolled in successive
steps to produce anyone of the many
required shapes. Rolling is the most common
method of shaping. https://www.britannica.com/technology
/steel/Continuous-casting
Once shaped, steel may be coated with
other metals such as zinc or tin, or with
organic coatings like paint or PVC.
CONTINUOUS CASTING
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VIDEOS ABOUT THE TOPIC FOR
ADDITIONAL INFORMATION. THANK
YOU!