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Steel is one of the invisible heroes of modern life. It forms the foundation of many products we use daily and appears in countless areas that make our lives easier.
So, how is steel made? The answer to this question is actually part of humanity’s journey of technological development.
Think about it: From the skeletons of our houses, to the household appliances we use, from cars to bridges, steel is indispensable in many structures and vehicles.
That is precisely why understanding steel production processes means not only learning how a metal is created but also how our lives are shaped.
Even more importantly, steel is becoming not only strong but also a sustainable material.
Thanks to advancing technologies, it is now possible to produce steel with less environmental impact. At this point, the concept of “steel production” gains critical importance not just for industry but for our future as well.
Now, aren’t you curious how this magical material comes into being? Whether by using scrap or starting from ore…
Steel production is the result of centuries of accumulated knowledge and technological transformation.
In the following sections, we will explore step by step how steel is produced, what methods are used, and which raw materials play a role in steel’s journey.
But first, let’s say this:
Steel is not just a metal; it is a milestone that has played a leading role in shaping human civilization, symbolizing strength and durability.
Are you ready to dive deep into this unique story and discover how humanity’s history has been transformed by steel?
The history of steel production runs almost parallel to humanity’s own development process. So, how did this strong and durable material emerge, and how has it evolved over time?
Here is a glimpse into the fascinating journey of steel…
In ancient times, people encountered not pure iron but iron ores found in nature.
However, the question of how to make steel was unanswered back then because technical knowledge and equipment were not as developed as today. Processing iron was a great revolution for humanity, but steel production marked the real beginning of the industrial revolution.
By the Middle Ages, blast furnaces were invented, making it possible to produce pig iron. Then, by converting this pig iron into steel, metals emerged that changed our lives—from weapons to agricultural tools, bridges to building structures.
At this point, the concept of “iron and steel production” was born and began to develop.
In the 19th and 20th centuries, especially with the industrial revolution, steel production took a great leap forward. Thanks to new production methods and technological innovations, more durable, lighter, and more flexible steels started to be produced. For example, modern methods such as the Basic Oxygen Furnace (BOF) and Electric Arc Furnace (EAF) used in crude steel production significantly increased production capacity and quality.
Today, steel production is not just a process that happens in large factories; it is also at the center of sustainability and eco-friendly approaches. As steel production methods evolve, technologies that consume less energy and cause less environmental damage have also entered our lives. For example, new-generation approaches like green steel production are preparing to revolutionize the future of steel manufacturing.
In short, the journey of steel is a long and challenging adventure in which humanity has danced with technology. This journey continues not only with production techniques but also with the diversity of steel’s application areas. As a fundamental pillar of modern life, steel becomes an increasingly important material every day.
When it comes to steel production, the first question that usually comes to mind is: How is steel obtained? The answer depends on the type of raw material used because steel is produced either by recycling scrap metals or starting from ore. Now, let’s focus on these two main methods.
Recycling scrap metals back into steel is extremely important both economically and environmentally. The Electric Arc Furnace (EAF) technology is used precisely for this purpose. Scrap iron and steel materials are melted at high temperatures to become ready for reuse.
Why is this method so preferred? Because using scrap consumes less energy compared to production from ore and reduces carbon emissions. This opens the door to sustainable steel production.
Another important method is the production process starting from ore. Iron ore is processed in blast furnaces to produce pig iron. Then, in the Basic Oxygen Furnace (BOF), this pig iron is refined by removing carbon and other impurities to convert it into steel.
This method is ideal for large-volume productions, and blast furnaces used by integrated steel producers worldwide constitute a large portion of steel production from ore.
Both methods have their unique advantages; however, today there is a growing interest in EAF technology in steel production processes due to its energy efficiency and lower environmental impact.
Steel production technologies are constantly evolving. However, the vast majority of methods used worldwide are based on two main technologies. Curious to know what these methods are? Let’s explore them together!
The Electric Arc Furnace method plays a leading role especially in steel production from scrap. Here, scrap steels are melted at high temperatures by electric arcs and transformed into pure steel. This method is highly important in terms of energy efficiency and environmental sustainability. Additionally, the shorter production time makes EAF attractive.
Steel production with electric arc furnaces is continuously advancing thanks to improved technologies, aiming for lower carbon emissions. Leading companies like Hasçelik invest heavily in this technology to secure a prominent position in the future of steel production.
The other dominant method, which accounts for the majority of global steel production, is the combination of blast furnace and basic oxygen furnace. In this process, iron ore is processed in the blast furnace to produce pig iron; then this pig iron is converted into steel using the basic oxygen furnace.
This method is suitable for large-scale productions and is commonly used in high-capacity plants. However, it requires more resources in terms of energy consumption and carbon emissions compared to the EAF method.
Although steel production varies depending on the method used, it essentially consists of several common stages. Understanding these stages is essential to grasp how steel becomes so durable and high-quality!
If you’re ready, let’s take a step-by-step look at the fundamental production processes.
Everything starts here. Iron ore is processed in blast furnaces to obtain pig iron. At this stage, impurities in the ore are separated, resulting in pig iron, the basic building block of steel.
Pig iron is not steel yet. Excess carbon and other impurities must be reduced. This stage involves refining using the basic oxygen furnace or electric arc furnace. Here, pig iron reaches the desired chemical composition and purity.
After refining, alloying elements are added to give steel specific properties. Elements like chromium, nickel, and vanadium enable steel to acquire superior characteristics for different purposes. For example, specialty engineering steels are produced at this stage.
The future of steel production is shaped by eco-friendly and innovative methods. Techniques like hydrogen reduction aim to reduce carbon emissions. Thanks to these technologies, steel production becomes greener and more sustainable.
• Feeding Molten Steel into the Casting Machine: Molten steel from the electric arc furnace or other refining processes is continuously fed into the casting machine.
• Casting Mold and Cooling: The mold shapes the steel, and a cooling system solidifies it in a controlled manner.
• Pulling and Cutting: The solidified steel is continuously pulled from the casting machine and cut into desired lengths.
• Formation of Semi-Finished Products: Semi-finished products called slab, bloom, or billet are prepared for subsequent shaping processes.
Steel production cannot be imagined without quality raw materials because the materials used directly affect the steel’s quality, durability, and characteristics. Although the raw materials differ between the electric arc furnace (EAF) and blast furnace-basic oxygen furnace (BF-BOF) methods, both rely on carefully selected materials.
The EAF method works by recycling scrap metal. The main raw material here is a high proportion of scrap steel. Scrap melts thanks to the electric arc and is transformed back into steel. This method stands out due to its environmental friendliness and energy savings.
Additionally, alloys (alloying elements) and electrodes are used during melting to improve quality. The higher the scrap quality, the superior the properties of the produced steel. Companies like Hasçelik expertly manage this delicate balance in steel production from scrap.
Approximately 75% of the raw materials used in steel production by EAF come from scrap steel. Scrap allows for direct recycling into high-quality steel and plays a critical role in reducing the carbon footprint.
The remaining raw materials are distributed as follows:
• About 15% consist of direct reduced iron (DRI) and hot briquetted iron (HBI), which are iron products reduced at high or low temperatures.
• The remaining approximately 10% consists of pig iron and hot metal.
This mix of raw materials provides energy efficiency in production and allows steel to be produced with desired properties. For example, the use of DRI and HBI ensures continuous supply of quality raw materials when scrap stocks are insufficient.
The blast furnace method uses natural resources such as iron ore, coke, and limestone.
• Iron ore: The fundamental building block of steel.
• Coke: Serves as fuel and reducing agent in the blast furnace.
• Limestone: Binds impurities in the furnace to form slag.
The pig iron obtained from the blast furnace is refined in the BOF, where oxygen removes carbon and other unwanted elements. The raw materials and energy intensity of this process are critically important for production efficiency and environmental impact.
Pig iron is produced by the reaction of iron ore with coke in the blast furnace. During this process, iron ore is reduced into molten hot metal (pig iron). However, pig iron contains about 3-4% carbon and various impurities (such as sulfur and phosphorus), making it brittle and difficult to work with.
The second stage of converting pig iron to steel is refining. This stage usually takes place in high-temperature environments such as the Basic Oxygen Furnace (BOF) or Electric Arc Furnace (EAF). During refining, excess carbon, sulfur, phosphorus, and other unwanted elements are removed or minimized. This is done through oxygen blowing, addition of alloying elements, and controlled stirring techniques.
After refining, steel is enriched with alloying elements to gain desired mechanical and chemical properties. Elements like nickel, chromium, and manganese are added at this stage. Also, precise adjustments in temperature, carbon content, and other parameters lead to the production of different grades of specialty steels suitable for various applications.
Continuous casting is a method where molten steel is continuously cooled and solidified inside special molds, directly forming semi-finished products. This technique consumes less energy compared to traditional methods, shortens production time, and minimizes material waste. Thanks to continuous casting, structural homogeneity in steel improves, internal defects decrease, and production quality is enhanced.
Today, a large portion of the world’s steel production is shaped using this method. Its high production speed and energy efficiency also reduce environmental impacts. Especially in modern facilities like Hasçelik, continuous casting technology lies at the heart of steel production.
Ingot casting involves pouring molten steel into large molds where it cools and solidifies into large blocks called ingots. These blocks are then converted into final products through shaping processes such as rolling or forging. Ingot casting is preferred for cases that require high purity and special alloys.
However, this method is not as fast or efficient as continuous casting; production times are longer, and material waste can be higher. Still, it remains indispensable for steel types requiring high strength and special quality.
Among the most pioneering technologies in steel production today, the Electric Arc Furnace (EAF) forms a cornerstone of Hasçelik’s modern production philosophy. EAF technology is designed with environmental sustainability and high efficiency goals, serving as a leading method in scrap-based steel production.
One of Hasçelik’s most important investments is the Consteel preheating system. This system preheats scrap metal in a special furnace before entering the electric arc furnace, allowing the scrap to reach a high temperature without being melted by electrical energy alone. This reduces the energy demand for melting.
Thanks to Consteel technology:
• Energy consumption is reduced by up to 20%,
• The efficiency of EAF furnaces increases,
• Production time shortens,
• Environmental emissions significantly decrease.
EAF steel production is based on rapidly melting scrap and other recycled materials using high electrical energy. Compared to the classical blast furnace-basic oxygen furnace (BF-BOF) method, it offers more flexible and environmentally friendly production. EAF technology is especially preferred for reducing carbon footprint and saving energy.
Hasçelik operates one of the most modern steel plants in Turkey and the region equipped with EAF technology. With a high level of automation, energy efficiency, and eco-friendly approaches, Hasçelik makes a difference both in product quality and production sustainability. Furthermore, by using advanced electrodes and state-of-the-art control systems, the processes are optimized to minimize waste and energy loss.
By utilizing EAF technology, Hasçelik not only produces high-quality steel but also leads the way toward cleaner and greener production goals. The predominant use of scrap contributes to conserving natural resources, while its potential compatibility with next-generation hydrogen reduction technologies positions Hasçelik as a key player in the future of steel production.
