Method 1: The process of making steel using blast furnace (BF) and basic oxygen furnace (BOF) involves the use of raw materials like iron ore, coal, limestone, and recycled steel to create crude steel.
Method 2: Utilizing recycled steels, direct reduced iron (DRI), or hot metal, and electricity, the electric arc furnace (EAF) process is another way to produce crude steel.
Approximately 70% of the world’s steel comes from the BF/BOF method, with EAF production making up the remaining 30%.
The blast furnace ironmaking process relies heavily on iron ore and metallurgical coal. Coking coal is turned into coke, a type of carbon used as both fuel and a reducing agent.
On average, it takes 1.6 tonnes of iron ore and about 450kg of coke to make a single ton of pig iron.
Importance of Iron
Iron plays a vital role in steel production, especially in high-grade ores containing 60%-65% iron. Australia and Brazil are the top exporters of iron ore worldwide.
Global iron ore reserves surpass 800 billion tons, with an estimated 230 billion tons of iron available.
| Position | Countries Leading in Iron Ore Production | 2023 |
|---|---|---|
| 1 | Australia | 300 million metric tons |
| 2 | Brazil | 280 million metric tons |
| 3 | China | 210 million metric tons |
| 4 | India | 150 million metric tons |
| 5 | Russia | 110 million metric tons |
| 6 | South Africa | 80 million metric tons |
| 7 | Ukraine | 70 million metric tons |
| 8 | Canada | 60 million metric tons |
| 9 | United States | 55 million metric tons |
| 10 | Sweden | 50 million metric tons |
Thousands of tonnes
Coking Coal and Steel Production
The production of steel relies heavily on coking coal, which is mixed with iron ore during the reduction process to create steel.
Approximately 1 billion tonnes of metallurgical coal are used each year in steel production, accounting for 15% of global coal consumption.
China leads in coking coal production, while Australia dominates the export of metallurgical coal.
The Pulverised Coal Injection (PCI) technology can reduce coal usage in steel production by up to 30%.
Steel Recycling
Scrap steel is a valuable raw material in steelmaking, with an annual consumption of 650 million tonnes for steel production.
The use of recycled steel results in significant energy and raw material savings during steel production.
Electric Arc Furnaces (EAFs) can incorporate up to 100% recycled steel, while Basic Oxygen Furnaces (BOFs) can utilize up to 30%.
The steelmaking process effectively eliminates impurities from scrap steel, ensuring high-quality steel products.
Steel production materials are among the most significant commodities globally in terms of production, consumption, and transportation. For instance, iron ore ranks as the third-largest commodity by production volume, trailing only crude oil and coal, and as the second-most traded commodity, after crude oil.
Globally, ferrous scrap stands out as the most extensive commodity recycling activity, with a recycling volume exceeding 800 million tonnes.
Notes:
- Scrap consumption: Global scrap consumption figures are estimated based on assumed crude steel production, the share of different routes in total steel production, and raw materials charge rates. Therefore, these estimates may have a higher margin of error compared to other statistics such as crude steel production and iron ore consumption.
- Scrap availability: Estimates of scrap availability are based on modelling steel containing goods and structures’ lifecycles. This approach is data and assumption-intensive and does not consider certain policies’ potential impact. Despite possible discrepancies, these estimates provide a reasonable outlook on scrap supply changes over the medium term.
About steel
Steel stands as the most crucial material in engineering and construction globally. It boasts the unique ability to be recycled repeatedly without losing its properties. Learn more about it.
Imagine the intrigue that engulfed prehistoric humans upon encountering an unknown metal object. Questions on its origin and creation could linger indefinitely without inquiry. Mysteries still cloak our world, waiting to be unveiled.
This blog aims to unravel such mysteries and provide insights into the human experience. Enjoy the journey!
Metal is a chemical element comprising various pure or alloyed substances with high luster, malleability, and conductivity of heat and electricity. It denotes any metallic compound derived from its elemental composition.
Metals are efficient conductors of heat and electricity. Certain metals like iron, nickel, and others can be dissolved in acids to form salts and are predominantly classified as transition metals, with a few exceptions.
Metals are typically extracted from ores, which are rocks or minerals that contain a high concentration of the desired metal. The process of extracting metals from ores involves various techniques such as crushing, grinding, and heating to separate the metal from the ore. This process, known as metallurgy, has been developed over thousands of years and continues to evolve with advances in technology.
Once metals are extracted from their ores, they undergo further processing to improve their purity and properties. For example, iron is often smelted in a blast furnace to remove impurities and carbon, resulting in steel, a stronger and more versatile metal. Other metals, such as copper and aluminum, are refined through electrolysis or other chemical processes to achieve the desired characteristics.
In addition to natural sources of metals, recycling plays a crucial role in metal production. Recycling scrap metal not only conserves valuable resources but also reduces energy consumption and environmental impact. Recycling facilities use various methods to sort, shred, and melt scrap metal to create new products, helping to close the loop on the metal production process.
One of the most common metals found on Earth is iron, which is essential for the production of steel, a vital material used in construction, manufacturing, and many other industries. Iron ore is typically mined and then processed through a blast furnace to extract the iron metal. This process involves the reduction of the iron ore using carbon monoxide, resulting in the formation of molten iron and slag.
In addition to iron, aluminum is another widely used metal that is extracted from bauxite ore through a process called the Bayer process. This method involves dissolving the aluminum ore in a caustic soda solution to extract the aluminum hydroxide, which is then heated to produce pure aluminum metal.
Metal production has come a long way from its early beginnings, with advancements in technology enabling more efficient and environmentally friendly methods of extraction and processing. As we continue to innovate and explore new possibilities, the future of metal production looks promising.
Something Precious (Metal in Ancient Times)
During the Bronze Age, humans pioneered the discovery and production of metal artifacts. Metals like gold, silver, and other non-ferrous metals were deemed valuable for tools and artistic embellishments.
However, their soft nature made them less suitable for structural applications and were primarily reserved for decorative purposes.
Metal in History
The earliest recorded metal usage dates back to the Olenekian culture in Eastern Europe, predating the last ice age by around 27,000 years.
Metals such as gold, silver, copper, and other non-ferrous metals symbolized status and social hierarchy, spreading across continents through trade networks.
In the early 20th century, metals found diverse applications in everyday life, from smartphones to vehicles, airplanes, and infrastructure. Hardware stores continue to serve as go-to destinations for metal products like nails and screws for repairs and construction work.
Wrap Up
Metal embodies the backbone of modern human technology, integral to various aspects of our lives. Delving deeper into the secrets of metal can enrich our understanding and pave the way for future advancements.
Exploring the origins of metals is key to understanding the importance of recycling. Recognition of the effort involved in obtaining materials sheds light on the necessity of finding energy-efficient sources.
This guide delves into the origins of certain metals and explores their recycling processes. Click on the embedded links within this article to discover more.
How are metals found in nature?
Most pure metals originate from the Earth’s crust, extracted from solid materials known as ores containing minerals and metallic compounds. Iron constitutes nearly a third of the planet’s mass, predominantly found at the core. Magnesium, nickel, and aluminum account for 14%, 1.5%, and 1.4% respectively, totaling 49% of the planet’s content. Precious metals like gold, silver, platinum, and palladium exist in trace amounts.
Extensive mining operations are essential to extract metallic ores from the ground, with minerals often existing in low concentrations within rocks, necessitating significant excavation efforts. For example, copper mostly occurs in sulphide ores with as little as 0.25% copper content.
Which country produces the most metal?
Australia and Brazil lead the global iron ore production, with Australia contributing half of the world’s iron ore exports and Brazil exporting approximately 23% of the global iron exports in 2020.
In 2020, Brazil held reserves of 15 billion metric tons of iron content and 34 billion metric tons of crude ore, with a production of 400 million metric tons of iron ore in the same year. For the latest statistical data, visit the following link.
Global events have a significant impact on the metal and scrap metal market. For instance, ASM analyzed how the scrap metal market was affected by the coronavirus outbreak.
Metals in their pure form are naturally sourced from the earth. They are typically categorized as ferrous or non-ferrous. Ferrous metals, such as mild steel, carbon steel, and cast iron, contain iron, while non-ferrous metals like copper, aluminium, tin, and lead do not have iron content.
The extraction and refinement of metals from ores involve various processes. This may include crushing the ore into powder, heating it at high temperatures, using a chemical bath to separate pure metals, and applying electric current to remove impurities. Below are some common metals and their extraction methods:
– Aluminium: Extracted from bauxite through electrolysis.
– Zinc: Produced using froth flotation or smelting.
– Lead: Extracted through flotation and further heating.
– Copper: Separated from low copper content ores through heating.
Mixing different metals to create alloys enhances their properties. For example, bronze, a combination of copper and tin, is stronger than pure copper. Steel, an alloy of iron and carbon, is versatile and used for various applications.
Metal recycling is possible, but the methods vary depending on the type of metal. It is recommended to research the recycling process specific to each metal. Refer to ASM’s guide on metal recycling for detailed information.
ASM Metal Recycling acquires a wide range of ferrous and non-ferrous scrap metals, providing competitive prices for recyclable materials.