RAW MATERIALS :

1. Sources of Metallic Iron

2. Oxidizing agent
3. Fluxes
4. Sources of Heat
5. Deoxidizers and alloying additions.
6. Furnace refractories.
* Sources of Metallic Iron (PRIMARY SOURCE)

A) Molten iron from Blast Furnace (Hot Metal)

B) Solid pig Iron (from Blast Furnace)
C) DRI

Secondary source
Steel scrap (basically process scrap)
SCRAP LOAD FOR VARIOUS PRODUCT

PRODUCT SCRAP (% of Ingot)

Rails 20-25
Plates 20-50
Wheels, axles 35-45
Strip 15-30
Merchant products 15-20
Forgings 30-45
 % Scrap consumption in Various process

100
100
75
80

60 45 45
40 25 25
8 12 12 12
20

0
Bessemer open Electric LD LD kaldo Rotor Bessemer open Electric
hearth (Modified) hearth

Modified Conventional
Conventional Process Oxygen steelmaking Process
Process
Oxidizing agent

Iron oxide (Iron Ore, Mill scale)

Air (O2+N2)
Oxygen gas (purity 99.5%)
 Fluxes
Flux %CaO %S %MgO %SiO2 %Al2O3 %Fe2O3 %CaF2 %TiO2

Lime 90-95 0.1-0.2 2-3 1.5 - - - -

Limestone 50 0.01 1 1 - - - -
Calcined Dolomite 55 0.1 34-38 3-4 - - - -
Ganister 0.5 - 0.1 94 - - - -
Fluorspar - - - 10 - - 75-85 -
Bauxite - - - 1-2 54-56 11-14 - 1-2
Sources of Heat

Exothermic oxidation of impurities.

Bessemer and BOF- Difficulty in taking cold
charge.
Pulverised fuel,oils, natural, coke oven, Blast
furnace gasses can be used to retain heat inside
steel making furnace.
 Deoxidisers & Alloying Elements
Alloying elements Effects
Aluminum (Fe-Al) Restricts grain growth, deoxidizer to control grain size.
Silicon (Fe-Si) Deoxidizer, improves strength, hardenability, electrical property
Manganese(Fe-Mn) Weak deoxidizer than Si, Improves strength & toughness
Nickel Not deoxidizer, improves toughness & impact strength (low
temp), hardenability, corrosion resistance.
Chromium (Fe-Cr) Not deoxidizer, improves high temperature strength, corrosion
and wear resistance, hardenability
Titanium (23-25%) Strong deoxidizer, refines grain, improves strength, Nuutralises
the effect of N2 in steel. (Fe-Ti)
Molybdenum Pronounced effect on hardenability, improves creep, corrosion
resistance & high temperature strength.
Vanadium (35%) Strong deoxidizer, improves strength, impact resistance (Fe-V)
Boron (5%B), Fe-B Deoxidiser, improves hardenability % mechanical properties,
Zirconium (40%Zr) Deoxidizer, decrease the bad effect of N2 & S (Zr-FeSi)
Niobium (50%) Improves plasticity, Corrosion resistance, weld properties (Fe-Nb)
Furnace Refractories

Acid Furnaces : Silica sand, Ganister

Basic Furnaces : Dolomite, Dolomite+Magnesite
Magnesite Chrome (Magnesite+chromite)