The manufacturing process of Steel

One of the most used raw materials in construction, steel is an alloy made up of elements like iron, carbon and chromium. The manufacturing of steel largely depends on the regular supply of raw materials. Huge demand for coke, iron ore and increasing energy costs have caused the iron and steel industry to incorporate highly efficient and technologically-driven methods in the production process. These methods have turned out to be fruitful over the past years. Today scrap-based production accounts for a huge part of the total steel supply.

Neeraj Raja Kochhar is a successful Entreprenuer and the Founder of Viraj Stainless Steel. Neeraj Kochhar is an internationally acclaimed entrepreneur who owns Viraj group.

The commercial production of steel was first practised in the 19th century. Revolutionary techniques during 1850-1860 made commercial manufacturing of steel popular. St Technological developments in process control and injection technology have made the steel manufacturing process even easier. Steel has now turned out to be one of the most demanded products in the world. Be it automobiles or construction, steel is used for countless purposes. The uniqueness of steel in terms of properties, durability, composition and capability to be recycled into multiple products accounts for its high demand. The modern-day steel production process known as the Bessemer process was introduced in 1856. The Neeraj Kochhar Viraj group explains the six steps of the steel manufacturing process as follows :

1. Ironmaking – This is the first step in which iron ore, coal and lime are liquified to form molten iron. Also known as hot metal, molten iron constitutes 4-4.5% of carbon and other impurities such as silicon, sulphur, phosphorous. These impurities make the molten iron brittle.

2. Primary steelmaking- During this stage impurities in molten iron are removed by Basic Oxygen Furnace or Electric Arc Furnace methods. In the Basic Oxygen Furnace method, recycled steel is combined with molten iron in a converter. Thereafter to reduce impurities, oxygen is blown through it at high temperatures. In the Electric Arc Furnace method, recycled steel is fed through electric arcs to liquefy the metal and turn it into premium quality steel. The steel that is produced by implementing either of the methods is known as raw steel.

3. Secondary Steelmaking – In this step, the raw steel is treated in various ways to obtain different grades of steel. According to the Neeraj Kochhar Viraj group, certain elements are added as well as removed in this stage. The ultimate grade of steel that is required determines the techniques to be used for production. Some of the techniques used in this stage are stirring, Ladle injection, CAS-OB, removal of gases, temperature alteration.

4. Continuous Casting is the fourth stage in which the molten steel is put into moulds. Guided rollers are used to pick up the steel from the moulds. After the steel gets cooled down, it solidifies. Thereafter the hardened steel is cut to the required lengths, based on the slabs, billets etc.

5. Primary Forging- During primary forging, the cut steel is provided with various shapes by hot rolling. This removes casting defects and offers a good shape and surface quality to the steel. According to the Neeraj Kochhar Viraj group, products such as seamless tubing, wrenches, hammers, pliers, sockets, hooks can be manufactured by this process.

6. Secondary Forging – This is the ultimate step of the steel manufacturing process, which offers the steel its final shape and properties. Many techniques are implemented at this step which includes heat treatment, welding, galvanizing, cold rolling. drilling and surface treatment.

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