1. What is Steel ???
Steel is an Alloy of Iron mixed with
Carbon
To understand better , Lets go back around
1200 BC
2. It all started in the beginning
of ‘The Iron Age’
When mankind started the use of iron , for
generally weapons , hand tools
And pots . At first it was used as inferior to
Bronze , But due to the abundancy of iron on
earth , soon it became the most used metal
3. But the metal iron is never found on earth in its pure form , since the metal is very
reactive , It is found in forms of oxides in iron ores ,
The Iron had to be freed from the ore to
make it useable
Iron Ore is heated with Charcoal/Coke , Thus
the oxygen is removed from the Oxide ,
And molten iron is separated , which is
cooled to gain its metal form
4. Modernization demanded production of iron in huge quantity ,
Blast furnace was introduced to fulfill this growing demand .
Blast furnace does the same thing , mixing ore with coke, But
in Large Quantity ,
Due to the use of Coke , the iron contains a large
portion of Carbon in it ( more than 4% ) .
This is known as Cast Iron .
The Cast Iron is further heated and worked to reduce the
carbon to around 0.1% .
This is the purer form of iron , which is known as
wrought iron
5. Cast Iron
Percentage of Carbon
HARD
BRITTLE
TEMPARABLE
NON MALLEABLE
LOW TENSILE STRENGTH
LOW MELTING POINT(1200 degree C)
Presence of carbon makes the metal
hard and brittle
6. Wrought Iron
Percentage of Carbon
HIGH MELTING POINT (1500 degree C)
HIGH TENSILE STRENGTH
NON TEMPARABLE
MALLEABLE
DUCTILE
ELASTIC
SOFT
This is the purer form of Iron
8. HARD
BRITTLE
TEMPARABLE
NON MALLEABLE
LOW TENSILE STRENGTH
LOW MELTING POINT(1200 degree C)
HIGH MELTING POINT (1500 degree C)
HIGH TENSILE STRENGTH
NON TEMPARABLE
MALLEABLE
DUCTILE
ELASTIC
SOFT
+
Nickel ,Chromium ,
Titanium , Copper ,
Manganese etc.
10. Steel
Steel is a material with wide range of properties , with the availability of its base metal Iron in nature
The properties of steel depends on the percentage of carbon .
Bessemer’s process was the first process capable of mass production of steel ,Steel provided
higher tensile strength , ductility than cast iron with presence of hardness .
Soon Steel replaced cast iron as structural material , massive number of steel was produced for
railways ,
Steel created the platform , on which the modern industrialization is standing on . And
Steel also Made the stairs, using which it is climbing higher .
12. STEEL CAN BE BROADLY CATEGORIZED INTO FOUR GROUPS BASED
ON THEIR CHEMICAL COMPOSITION:
1. CARBON STEELS
2. ALLOY STEELS
3. STAINLESS STEELS
4. TOOL STEELS
13. Carbon Steels
Carbon steels contain trace amounts of alloying elements and
account for 90% of total steel production. Carbon steels can
be further categorized into three groups depending on their
carbon content:
Low Carbon Steels /Mild Steels : Contain up to 0.3%
carbon
Medium Carbon Steels : Contain 0.3-0.6% carbon
High Carbon Steels : Contain more than 0.6% carbon
14. Alloy Steels
Alloy steels contain alloying elements (e.g.
manganese, silicon, nickel, titanium,
copper, chromium, and aluminum) in
varying proportions in order to manipulate
the steel's properties, such as its
hardenability, corrosion resistance,
strength, formability, weldability or
ductility. Applications for alloys steel
include pipelines, auto parts, transformers,
power generators and electric motors.
15. Stainless Steels
Stainless steels generally contain between 10-20% chromium as the main alloying
element and are valued for high corrosion resistance. With over 11% chromium,
steel is about 200 times more resistant to corrosion than mild steel
16. Tools Steels
Tools steels contain tungsten, molybdenum, cobalt and vanadium
in varying quantities to increase heat resistance and durability,
making them ideal for cutting and drilling equipment.
It can also be divided by their shapes and related applications:
Long/Tubular Products include bars and rods, rails, wires, angles,
pipes, and shapes and sections. These products are commonly
used in the automotive and construction sectors.
Flat Products include plates, sheets, coils, and strips. These
materials are mainly used in automotive parts, appliances,
packaging, shipbuilding, and construction.
Other Products include valves, fittings, and flanges and are mainly
used as piping materials.
22. 1.Tensile Strength:
Tensile strength is the amount of stress that a substance can take before
becoming structurally deformed. The tensile strength of steel is
comparatively high, making it highly resistant to fracture or breakage,
which is a key point in its use in infrastructure building.
2.Ductility:
One of the useful mechanical properties of steel, is its ability to change
shape on the application of force to it, without resulting in a fracture. This
property is known as ductility, which enables it to be used in the making
of different shapes and structures ranging from thin wires or large
automotive parts and panels.
3.Higher Strength to weight ratio
Steel provides a higher strength compared to its weight , so steel structures gains
strength without increasing the weight of the structure
23. 3. Malleability:
Malleability is closely linked with ductility, and allows steel to be deformed
under compression. It allows this alloy to be compressed into sheets of
variable thicknesses, often created by hammering or rolling.
4. Durability:
The hardness of this alloy is high, reflecting its ability to resist strain. It is
long-lasting and greatly resistant to external wear and tear. Hence it is
considered a very durable material.
5. Conductivity:
Steel is a good conductor of heat and electricity. These properties make it
good choice for making domestic cookware, as well as electrical wiring.
24. 6. Luster:
One of the physical properties of steel is its
attractive outer appearance. It is silvery in
color with a shiny, lustrous outer surface.
The addition of certain elements, makes
some types of steel resistant to rust. Stainless
steel for instance contains nickel,
molybdenum and chromium which improve
its ability to resist rust.
26. Steel is a widely used construction material across
the world.
The steel industry is the second largest one globally
after the oil and gas industry, with an approximate
turnover of $900 billion USD.
27. Previous stage steel industry
Before about 1860, steel was an expensive product, made in
small quantities and used mostly for swords, tools and cutlery;
all large metal structures were made of wrought or cast iron.
The introduction of cheap steel was due to the
Bessemer process.
28. • Bessemer process
The Bessemer process was the first
inexpensive industrial process for the mass
production of steel from molten pig iron . The
key principle is removal of impurities from
the iron by oxidation with air being blown
through the molten iron. The oxidation also
raises the temperature of the iron mass and
keeps it molten.
29. • Oxidation
The blowing of air through the molten
pig iron introduces oxygen into the
melt which results in oxidation,
removing impurities found in the pig
iron, such as silicon, manganese,
and carbon in the form of oxidies .
These oxides either escape as gas or
form a solid slag.
• Bessemer process
30. When the phosphorus content is high, dolomite, or
sometimes magnesite are used to remove them.
When the required steel had been formed, it was
poured into ladles and then transferred into
moulds while the lighter slag was left behind. The
conversion process, called the "blow", was
completed in approximately 20 minutes. During
this period the progress of the oxidation of the
impurities was judged by the appearance of the
flame issuing from the mouth of the converter.
32. Methods for manufacturing steel have evolved
significantly since industrial production began in the
late 19th century.
Modern methods, however, are still based on the
same premise as the original Bessemer Process, which
uses oxygen to lower the carbon content in iron.
34. Basic Oxygen Furnace
To put it simply, basic oxygen steelmaking is a
means of producing steel by using oxygen. The
word “basic” refers to the pH of the refractories
lining the ladle interior. This process is one of the
worlds leading methods for producing steel, and
since its implementation . In a BOF there is six
steps
1. Charging the scrap metal into the furnace.
2. Charging the hot metal.
3. Blow the Oxygen into the furnace.
4. Taking the sample of the melting metal.
5. The vessel is tilted and the steel is tapped off
below the slag level.
6. The slag is removed by tilting the vessel in the
opposite direction.
35.
36. Advantages of Basic Oxygen Furnace
• High production rate . About 250 ton steel per
hour
• High steel quality
Disadvantages of Basic Oxygen
Furnace
• Weak controlling Iron composition
• High Cost required
37. Electric Arc Furnaces (EAF)
• Electric Arc Furnaces (EAFs) are used to produce carbon
steels and alloy steels primarily by recycling ferrous
scrap. In principle an electric arc is formed between the
electrode and the metallic charge and charge is heated
from the arc radiation. Electric arc furnaces are of two
type
• Alternating current
• Direct current.
38. In alternating current, furnace operates by means of electric
current flowing from one electrode of three to another through
the metallic charge. These types of furnaces are used for melting
of non-ferrous metals such as brass, copper and zinc.
is based on the heat generated by an electric arc.
In direct current, the current flows from carbon electrode, which
acts as cathode, to an anode embedded in the bottom of the
furnace.
41. Advantages of Electric Arc Furnaces (EAF)
• Lower investment
• Steady performance
• pollution free
Disadvantages of Electric Arc Furnaces
(EAF)
• Lost of sound levels
• the movement of scrap through the locality can cause
health hazards.
• Electric arc steelmaking is only economical where
there is plentiful electricity
42. Comparison between Basic Oxygen
Furnace(BOF) and Electric Arc Furnaces
(EAF)
BOF
1. common inputs for BOF
steelmaking are iron ore
and coal.
2. Raw materials are
comparatively costly.
3. Comparatively more
wastage.
4. More environmental
pollution.
EAF
1. the EAF furnace operates
using scrap steel.
2.Raw materials are
comparatively cheap.
3.Comparatively less
wastage.
4.Less environmental
pollution.
43. The molten steel is then deliver to Ladle Furnace ,
Modern structures require high quality Steels that can provide
the maximum amount of its capability ,
So the quality and composition of Steel must be Accurate ,
That’s why the proper refining of steel is a mandatory task .
Ladle furnace is used to Refine and to control
the quality of Steel
44. Then the molten metal from the Ladle furnace is cooled and given Shape through
Continuous Casting
The metal goes through the tundish where it is cooled with spray of water inside a mold
, and thus steel gets its solid shape .
45. But the Solid Shape is not the final Shape of product , rather they are made as Semi-
finished shapes. Mainly …..
1. Slab
Rectangular , width is greater than 2X of thickness
2. Bloom
thickness more than 6” , width lesser than 2X of thickness
3. Billet
Square or circular cross section , lesser than bloom
Slab Bloom Billet
46. Each provide different types of products ,
Then the Semi finished products go Further working , which gives them final shape and
Desired dimensions.
Slabs may be rolled in a plate mill or hot strip mill. Blooms are rolled in a bloom/billet mill to
produce billets. Billets are then further rolled in merchant bar mills (sometimes called bar mills)
or rod mills. Both slabs and blooms may go to a structural mill. The plate mill, hot strip mill,
billet mill, merchant and structural mills are all hot rolling mills.
47. Hot Rolling
The products go through reheating furnaces , where they are heated at a temperature higher
than the Recrystallization temperature (400 - 700)
Hot rolling increases the thickness of steel products .
Structural and bar products like rods and beems are made through hot rolling
.
48. Cold Rolling
Products are rolled at a lower temperature (generally room temperature )
Before cold rolling , The products are pickled with acid , which removes oxides from
surfaces.
With better surface characteristics than
hot rolled steel, it’s no surprise that cold
rolled steel is often used for more
technically precise applications, or where
aesthetics are important. But due to the
additional processing for cold finished
products, they come at a higher price.
49. Tube Making
In a typical operation to make welded pipe, hot rolled strip is heated and passed through a series
of specially grooved rolls. These curl the hot steel into the shape required, and press the hot,
bevelled edges together to form a weld. This is called "continuous butt welding".
Smaller diameter thin-walled tubes are used in furniture and light engineering applications, large
diameter heavy-walled pipes for water mains , high pressure gas and oil pipelines.
50. Coating
Cold rolled strip is often coated with metallic materials to protect the steel surface
or give the steel specific characteristics. Metallic materials used to coat steel
include mainly zinc, aluminium and tin.
Zinc Coating by Hot Dipping
53. Steel Industries in Bangladesh
Bangladesh is one of the Asia’s leading emerging steel markets & has a growing need for
raw materials and steelmaking technologies.
The movement towards a progressive national economy strongly depends on how
construction materials specially steels related industries have evolved and such products
are readily available.
Steel industry is an established and growing industry in Bangladesh.
Which has emerged as a major contributor to the national economy.
According to the experts, the growth of steel industry in Bangladesh is mainly induced by
the rapid expansion of the country's shipbuilding and real estate sector, as well as the
major investments in various infrastructure projects throughout the country.
54. The first ever steel mill was established in 1952 by the H Akberali Group of Industries as the
"Bangladesh Steel Re-rolling Mills (BSRM)". Located at Nasirabad, Chittagong, the plant
formed re-enforcing bars and structural sections.
The BSRM group added a captive billet manufacturing plants
in 1996 so as to make sure a stable distribution of billets of its
plants. In 2006, the company installed pilot cold rolling mill to
make ribbed high strength wires
By this time , Kabir group of industries established
KSRM Steel Plant Ltd , Their factory is situated at
Groramara , Sitakundu at Chittagong .
.
55. Now there are more than 400 active steel industries in Bangladesh .
Many steel producing companies have gained reputation as a brand. Among
them, GPH Ispat, BSRM, RSRM, KSRM, RRML, Anwar Steel, HKG Steel, AK Steel,
Rahim Steel, Abul Khair Group are worth mentioning.
56. Main products of Bangladeshi steel productions are TMT bars ,
Steel Sheets . For this production , billets and steel coils are
required ,
Some companies Import raw materials from outside , and some
produce billets for their purpose .
Steel Production of our country is scrap metal based ,
Bangladesh has a large Ship Breaking Capacity , which provides a
huge amount of scraps for steel production.
BSRM , the largest steel producer of the country , produces billets
from scrap metals , which is later used for making steel rods .
57. They heat scraps inside induction furnace , pass through ladle , and then make billets through
continuous casting .
Abul Khair is another leading steel industry of Bangladesh , for their TMT bars , they use scraps , pig iron
and heat them inside Electric Arc furnace ,
They are the first industry to install EAF in the process of our country .
Now they have two EAFs running ,
58. Abul Khair Steel also produces steel sheets , the raw material coils are imported
From abroad ,
These coils go through cold rolling process to make Steel Sheets that are used throughout
the country
Other companies like GPH , KSRM , they import billets from Europe , Japan , India and
use them for the re rolling process .
As for Bangladesh , we don’t have a vast collection of iron ores , we complement
the need with scrap metals , but steels made from scrap metals are known to lack
qualities than Steels made from iron ores ,
So for high quality steels , we have to import high quality billets and raw materials
from other countries .
62. Construction
THE MAJORITY OF STEEL GOES TO THE CONSTRUCTION
INDUSTRY. SUSTAINABLE STEEL STRUCTURES CAN BE
BUILT QUICKLY AT A LOW PRICE IN ITS VARIOUS FORMS
AND ALLOYS. THE DEVELOPMENT OF EFFICIENT STEEL
PRODUCTION TECHNIQUES AT THE END OF THE 20TH
CENTURY CONTRIBUTED TO THE GROWTH OF RAILWAYS
AROUND THE WORLD AS WELL AS THE ADVENT OF THE
HIGH-RISE BUILDING.
STEEL CAN ALSO BE FOUND IN:
i. EDUCATION AND HOSPITAL BUILDINGS
ii. SPORTS STADIUMS, STATIONS
iii. REINFORCED CONCRETE
iv. BRIDGE DECK PLATES
v. PIERS AND SUSPENSION CABLES
vi. HARBORS ETC.
63. Transportation
DIFFERENT TYPES OF STEEL ARE USED FOR THE CAR BODY,
DOORS, ENGINE, GEARBOX, STEERING, SUSPENSION, WHEEL
AXLES, AND INTERIOR. BESIDES THE AUTOMOTIVE MARKET,
STEEL IS FOUND IN TRANSPORT MATERIALS SUCH AS:
i. TRUCKS
ii. TRANSMISSIONS
iii. TRAINS
iv. RAILS
v. SHIPS
vi. ANCHOR CHAINS
vii. AIRCRAFT UNDERCARRIAGES
viii. JET ENGINES COMPONENTS
64. Energy
MANY OTHER ENERGY PROJECTS RELY ON LARGE AMOUNTS
OF STEEL:
i. OIL AND GAS WELLS AND PLATFORMS
ii. PIPELINES
iii. ELECTRICITY POWER TURBINE COMPONENTS
iv. ELECTRICITY PYLONS
v. WIND TURBINES
vi. TRANSMISSION TOWERS
vii. ELECTROMAGNETS
viii. TRANSFORMER CORES
ix. ELECTROMAGNETIC SHIELDS
65. Packaging
STEEL PACKAGING PROTECTS GOODS FROM WATER, AIR,
AND LIGHT EXPOSURE, AND IS FULLY RECYCLABLE. THIS
METHOD OF STORAGE HAS BEEN AROUND FOR OVER 200
YEARS.
STEEL ALLOWS FOR HIGH-SPEED FILLING AND
LIGHTWEIGHT, EASY TO OPEN PACKAGING. PACKAGING
STEELS ARE OFTEN MADE FROM LOW CARBON COLD-
ROLLED STEEL STRIP AND ARE SURFACE FINISHED. THE
STEEL IS TIN PLATED TO PREVENT CORROSION AND THEN
COATED WITH A POLYMER, LACQUERED, AND PRINTED. THE
MAJORITY OF STEEL PACKAGING GOES TOWARDS FOOD
AND BEVERAGE CONTAINER, FOLLOWED BY A GENERAL
LINE, AEROSOLS, AND CLOSURES (E.G., BOTTLE CAPS).
66. Appliances and Industry
ABOUT 75% OF THE WEIGHT OF TYPICAL
HOUSEHOLD APPLIANCES COMES FROM STEEL.
STEEL IS FOUND IN APPLIANCES LIKE FRIDGES,
WASHING MACHINES, OVENS, MICROWAVES, SINKS,
CUTLERY, ETC.
STEEL ALSO ACCOUNTS FOR MANY INDUSTRIAL
GOODS LIKE FARM VEHICLES AND MACHINERY,
STORAGE TANKS, TOOLS, STRUCTURES, WALKWAYS,
AND PROTECTIVE EQUIPMENT.
68. The world as we know it would not be the same
without the discovery and advent of steel. This
useful metal has a daily impact on our lives, far
more than we may even realize.
From the buildings we work and live in, the cars
we drive to the utensils we eat with, steel is
everywhere. Quite simply, the invention of steel
has helped to modernize the world and make it
a convenient place to live.
In fact, many would go so far as to say that the
development of mankind itself would have been
impossible without the invention of steel.
69.
70.
71.
72.
73.
74.
75. SOCIETAL IMPACT
The steel industry of today has helped to develop some of the world’s most forward-
thinking technologies. Essentially, it has created the ”age of convenience” in which we
now live.
Stainless steel, developed by British metallurgist, Harry Brearly, is used in most of
today’s gadgets, machinery, tools, household goods, and more.
From surgical tools to the hub caps on your car, to kitchen utensils, building materials,
and even furniture, stainless steel is extremely versatile.
Indeed, steel is the backbone and support of the global economy and infrastructure. It’s
a massive industry worth approximately $900 billion per year.
This being said, steel has some stiff competition from its close cousin in the industry,
aluminum. Today, there are 2,000 grades of steel, 1,500 of which are considered high
grades of steel.
There is still much potential for developing new grades of steel with a higher quality
grade, in a more environmentally manner as well.
77. The production of steel was ignited when Bessemer’s process was found in 1856, from then to the
recent days , the Manufacturing of Steel has changed itself as well the whole world.
And after the Open Heart Process was found , Capitalists created a revolution in the production of
steel ,
That was the birth of modern steel industries .
Now more or less , more than 50 countries contribute to the production of steel .
79. Export and Import of Steel
China is the highest exporting country and United States is the highest importing country
of Steel
80. Uses of Steel Products
China is also the top steel using country , with a high increasing rate ….
In 2007 EU was the second highest steel consuming region ,
But in 2017 , the usage has increased in Asia but has decreased in the EU ,
Which indicates the rapid growth of industrialization of Asia outside China and Japan .
India has played a major role in this growth .
82. The market size of Steel Industry in Bangladesh is about 300 billion US Dollars.
The industry grew from producing a merge 47,000 MT in 1971 to 4.0 million Mt in 2015.The production of
this sector expected to double about 8.0 million Mt on 2022 by the industrialists. In the last year, the total
production is 5.5 million MT, this year up to October production is 7 million tones & the capacity is about 8
million MT which indicates gradually expansion of steel industry in our country
83. The graph shows the per capita steel consumption in Bangladesh from
2010 to 2017
Which is very low compared to other leading countries , but the demand and consumption rate
is increasing per year due to progress in modern structure and industrialization.
In 2010 , per capita steel consumption was 24 kg , after seven years it has turned almost twice
of the previous amount .
In 2017 it was 45 kg per person .
84. To cater to the growing demand in coming days, other major industry players like KSRM and
GPH Ispat are also increasing their production capacity significantly. KSRM is undergoing an
expansion plan to expand its capacity by 45% in addition to its existing 0.4 million MT annually.
GPH Ispat also announced for a massive expansion of its re-rolling mill capacity from 0.12
million MT to 0.76 million MT per year and billet making capacity from existing 0.17 million MT
capacity to 1.0 million MT.
86. Steel is widely known because of its sustainability , Steel is 100 % recyclable ,
That means Steel can be used again and again without any defects in its
properties .
Steel is the most recycled material on the planet, more than all other materials
combined. Steel retains an extremely high overall recycling rate, which in 2014,
stood at 86 percent. The amazing metallurgical properties of steel allow it to be
recycled continually with no degradation in performance, and from one
product to another.
87. One ton of recycled steel saves:
642 kWh of electricity.
76 gallons of oil.
10.9 million Btu’s of energy.
4 cubic yards of landfill space.
2,500 pounds of iron ore.
Steel takes up to 100 years to fully degrade in a landfill.
Recycling steel takes 25% less energy and creates only 25% the water and air pollution
required to produce steel from raw materials.
About 70% of all metal is used just once, then discarded. The remaining 30% is recycled,
but after 5-cycles only 0.25% remains in circulation.
91. TYPICAL CARBON EMISSION FROM
STEEL INDUSTRY
THE GREENHOUSE GAS OF MOST RELEVANCE TO THE WORLD
STEEL INDUSTRY IS CARBON DIOXIDE (CO2).ON AVERAGE FOR
2017, 1.83 TONNES OF CO2 WERE EMITTED FOR EVERY TONNES
OF STEEL PRODUCED. THE STEEL INDUSTRY GENERATES
BETWEEN 7% AND 9% OF DIRECT EMISSIONS FROM THE
GLOBAL USE OF FOSSIL FUEL
THE AVERAGE CO2 INTENSITY FOR THE STEEL INDUSTRY IS 1,9
TONS OF CO2 PER TON OF STEEL PRODUCED. TAKING INTO
CONSIDERATION THE GLOBAL STEEL PRODUCTION OF MORE
THAN 1,3 BILLION TONS, THE STEEL INDUSTRY PRODUCES OVER
TWO BILLION TONS OF CO2.
STEEL IS AN ALLOY CONSISTING MOSTLY OF IRON, WITH A
CARBON CONTENT BETWEEN 0.02% AND 1.7 OR 2.04% BY
WEIGHT (C:1000–10,8.67FE), DEPENDING ON GRADE. CARBON IS
THE MOST COST-EFFECTIVE ALLOYING MATERIAL FOR IRON,
BUT VARIOUS OTHER ALLOYING ELEMENTS ARE USED SUCH AS
MANGANESE AND TUNGSTEN.
92. DIFFERENT KINDS OF POLLUTION DUE
TO STEEL MANUFACTURING
The steel industry releases large amounts
of pollutants into the air during all its
processes—be it while handling raw
material, producing iron and steel or
disposing of solid waste. ... The
main pollutantsare particulate matter,
oxides of sulphur and nitrogen and carbon
monoxide.
93. HOW TO CONTROL POLLUTION IN STEEL INDUSTRY
Pollution prevention techniques in EPA rules
Pollution prevention options can generally be characterized in
one of three categories:
Equipment changes (e-g., from byproduct recovery coke ovens to
non recovery coke ovens)
Process parameter changes (to borrow from another industry, e.g.,
lowering temperatures of mixing chambers where solvents are
being used; or addition ofcover fluxes to prevent oxidation)
Work practice changes (e.g., inspection and maintenance
programs)
101. Willi’s Tower ( Sears Tower)
The Willi’s Tower is situated in Chicago , USA.
It is one of the most famous Skyscrapers in the world . It
held the honor of the tallest building for a certain period .
But most importantly , It was designed by Bangladeshi
Architect , F R Khan , who is the father of the Architecture
of Skyscrapers