Steel is primarily made by combining iron with carbon, forming an alloy that typically contains less than 2% carbon. The carbon content strengthens the iron and improves its mechanical properties compared to pure iron. Other elements like manganese, chromium, nickel, and vanadium can also be added to enhance specific characteristics such as tensile strength, hardness, corrosion resistance, and fatigue resistance. The production of steel begins with smelting iron ore in a blast furnace or using an electric arc furnace, where iron ore, coal (or coke), and limestone are processed to produce molten iron. This molten iron, which contains too much carbon, is then refined in processes such as the basic oxygen furnace or electric arc furnace to reduce the carbon content and remove impurities. The resulting steel can then be cast into shapes and further worked by rolling, forging, or extrusion to create final products.

Key Components of Steel

• Iron: The base metal, sourced from iron ore.
• Carbon: The main hardening agent; usually less than 2%.
• Other alloying elements: Manganese, chromium, nickel, vanadium, etc., added to tailor properties.
• Small amounts of sulfur, phosphorus, silicon, and oxygen may also be present, though usually as impurities or controlled additions.

Steel Production Processes

• Blast Furnace-Basic Oxygen Furnace Route (BF-BOF): Converts iron ore into pig iron, then refines it into steel with controlled carbon and impurities.
• Electric Arc Furnace Route (EAF): Melts scrap steel and adds alloys to produce high-quality steel with energy efficiency and recycling benefits.

These processes allow steel to be produced in various forms, such as sheets, bars, beams, and wires, used widely in construction, automotive, appliances, and many other industries.