Introduction
Steel ingots are used as a basic raw material in various industries including rolling, forging and casting. In this article, we will examine the complete process of steel ingot production from the raw material stage to the final product.
Raw materials required
Iron ore (hematite and magnetite)
Metallurgical slag
Limestone
Sponge iron (DRI)
Steel scrap
Steel ingot production stages
1. Production of pig iron in a blast furnace (BF)
Iron ore enters the blast furnace after processing and pelletizing
It is melted at a temperature of about 1600 degrees Celsius
The final product is molten iron with 3-4% carbon
2. Production of steel in a basic oxygen furnace (BOF) or electric arc furnace (EAF)
Oxygen furnace:
Molten iron + 20-30% steel scrap
Pure oxygen injection to reduce carbon to 0.5-2%
Electric arc furnace:
90-100% steel scrap
Use of graphite electrodes and high electric current
3. Secondary metallurgy
Precise adjustment of the chemical composition in the ladle
Degassing operation under Vacuum
Adding required alloys
4. Continuous Casting
Molted steel is transferred to the continuous casting machine
Initial cooling in a copper mold (generator)
Cutting into standard lengths (6-12 meters)
Types of steel ingots
Bloom ingot: cross-section 150×150 to 400×400 mm
Billet ingot: cross-section smaller than 150×150 mm
Slab ingot: rectangular cross-section for sheet production
Important production standards
Iranian National Standard (ISIRI 3134)
ASTM A36 standard
DIN 17100 standard
Quality control in production
Chemical analysis with OES device
Mechanical tests (tensile, impact)
Surface defect inspection with ultrasonic testing
Ingot applications Steel
Raw material of rolling mills for the production of rebar and beams
Forging and blacksmithing industries
Production of industrial parts and machinery
Benefits of producing ingots by continuous casting method
Saving 15-20% in energy consumption
Reducing waste to less than 1%
Uniform quality throughout the ingot
Conclusion
The process of producing steel ingots is a complex combination of materials science and engineering that requires high precision in controlling production parameters. Shahrood Steel Company produces high-quality steel ingots by utilizing modern technologies and precise quality control.
