Steel
is an essential material for modern life. The manufacture of steels
delivers the goods and services that our societies need – healthcare,
telecommunications, improved agricultural practices, better transport
networks, clean water and access to reliable and affordable energy.
Global
steel production is dependent on coal. 70% of the steel produced today
uses coal. Metallurgical coal – or coking coal – is a vital ingredient
in the steel making process. World crude steel production was 1.4
billion tonnes in 2010. Around 721 million tonnes of coking coal was
used in the production of steel.
How is Steel Produced?
Steel is an alloy of iron and carbon. Steel is produced via two main routes
- Integrated smelting involving blast furnace (BF) iron-making followed by basic oxygen furnace (BOF)
- Electric arc furnaces (EAF).
Raw Materials
Steel
is an alloy based primarily on iron. As iron occurs only as iron oxides
in the earth’s crust, the ores must be converted, or ‘reduced’, using
carbon. The primary source of this carbon is coking coal.
Coke MakingCoking
coal is converted to coke by driving off impurities to leave almost
pure carbon. The physical properties of coking coal cause the coal to
soften, liquefy and then resolidify into hard but porous lumps when
heated in the absence of air. Coking coal must also have low sulphur and
phosphorous contents. Almost all metallurgical coal is used in coke
ovens.
The coking process consists of heating coking coal to
around 1000-1100ºC in the absence of oxygen to drive off the volatile
compounds (pyrolysis). This process results in a hard porous material -
coke. Coke is produced in a coke battery which is composed of many coke
ovens stacked in rows into which coal is loaded.
The coking
process takes place over long periods of time between 12-36 hours in the
coke ovens. Once pushed out of the vessel the hot coke is then quenched
with either water or air to cool it before storage or is transferred
directly to the blast furnace for use in iron making.
Iron MakingIron
ore is mined in around 50 countries – the largest producers are
Australia, Brazil and China. Around 98% of iron ore is used in
steel-making.
During the iron-making process, a blast furnace is
fed with the iron ore, coke and small quantities of fluxes (minerals,
such as limestone, which are used to collect impurities). Air which is
heated to about 1200°C is blown into the furnace through nozzles in the
lower section. The air causes the coke to burn, producing carbon
monoxide which reacts with the iron ore, as well as heat to melt the
iron. Finally, the tap hole at the bottom of the furnace is opened and
molten iron and slag (impurities) are drained off.
Basic Oxygen FurnaceThe
most commonly applied process for steel-making is the integrated
steel-making process via the Blast Furnace – Basic Oxygen Furnace.
In
the basic oxygen furnace, the iron is combined with varying amounts of
steel scrap (less than 30%) and small amounts of flux. A lance is
introduced in the vessel and blows 99% pure oxygen causing a temperature
rise to 1700°C. The scrap melts, impurities are oxidised, and the
carbon content is reduced by 90%, resulting in liquid steel.
Other
processes can follow – secondary steel-making processes – where the
properties of steel are determined by the addition of other elements,
such as boron, chromium and molybdenum, amongst others, ensuring the
exact specification can be met.
Optimal operation of the blast
furnace demands the highest quality of raw materials – the carbon
content of coke therefore plays a crucial role in terms of its effect in
the furnace and on the hot metal quality. A blast furnace fed with high
quality coke requires less coke input, results in higher quality hot
metal and better productivity. Overall costs may be lower, as fewer
impurities in the coke mean smaller amounts of flux must be used.
Around
0.6 tonnes (600 kg) of coke produces 1 tonne (1000 kg) of steel, which
means that around 770 kg of coal are used to produce 1 tonne of steel
through this production route.
Basic Oxygen Furnaces currently
produce about 70% of the world’s steel. A further 29% of steel is
produced in Electric Arc Furnaces.
Electric Arc FurnacesThe
Electric Arc Furnace process, or mini-mill, does not involve
iron-making. It reuses existing steel, avoiding the need for raw
materials and their processing. The furnace is charged with steel scrap,
it can also include some direct reduced iron (DRI) or pig iron for
chemical balance.
The EAF operates on the basis of an electrical
charge between two electrodes providing the heat for the process. The
power is supplied through the electrodes placed in the furnace, which
produce an arc of electricity through the scrap steel (around 35 million
watts), which raises the temperature to 1600˚C, melting the scrap. Any
impurities may be removed through the use of fluxes and draining off
slag through the taphole.
Electric Arc Furnaces do not use coal as
a raw material, but many are reliant on the electricity generated by
coal-fired power plant elsewhere in the grid.
Around 150 kg of coal are used to produce 1 tonne of steel in electric arc furnaces.
Pulverised Coal Injection
Pulverised
Coal Injection (PCI) technology involves injecting coal directly into
the blast furnace to provide the carbon for iron-making – displacing
some of the coke required for the process. A wider range of coals can be
used in PCI, including steam coal which has a lower carbon content than
coking coal. This method has a number of advantages, including reducing
overall costs and prolonging the life of existing coke batteries.
Recycling
Steel is 100% recyclable. The BOF process uses up to 30% recycled steel (scrap) and around 90-100% is used in EAF production.