The making of steel:

Earth, air and fire

From coarse and rocky iron ore to tough and shiny steel — the
making of the magic alloy is a fascinating journey that starts from
the crust of the earth, involves complex metallurgical reactions
and processes, and demands technological expertise of a high
degree. Tata Steel’s Jamshedpur plant, the very first steel plant in
India (production started in 1912), is today among the country’s
largest integrated steel-making facilities, producing 10 million
tonnes of steel every year. We walk through the modern Tata Steel
plant, much changed from its original manifestation, to witness
the birth of red hot molten steel in its multiple forms and its
casting as the radiant champion of industrial development.

By Shubha Madhukar
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or more than 3,000 years, humans have known how to make tools, weapons and
F ornaments from iron. Known as a metal of antiquity, iron is one of the building blocks
of modern civilisation. Indeed, there was a time when iron was more valuable than gold.

The basic process of making iron and its tougher alloy — steel — have not changed in
the last three millennia. First, the ore has to be found. Then it must be reacted with other
elements at very high temperatures. Third, the liquid steel must be collected and cast into
shape. And, finally, the steel must be treated to give it the properties needed for end use.

Steel is considered a green product because it is 100-percent recyclable and has an infinite
life cycle. Tata Steel is among the top 10 global steel companies and one of the world’s most
geographically-diversified steel producers, with operations in 26 countries and a commercial
presence in more than 50.

At Tata Steel’s Jamshedpur plant, the steelmaking process starts at the mines. Iron ore
is brought in by trucks from Noamundi in Jharkhand and Joda in Odisha, and coal comes
from West Bokaro and Jamadoba in Jharkhand and even as far away as Australia. The
Jamshedpur plant uses approximately 25 million tonnes of iron ore and coal/coke blend
every year to produce about 10 million tonnes of steel.

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The Tata Steel plant lights up the Jamshedpur skyline at twilight

The iron ore mine at Noamundi in Jharkhand

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One of the eight blast furnaces at the facility

Untreated ore cannot be used to make
steel as it reduces the quality of the metal.
Therefore, the raw iron ore is processed
at the sinter (or processed iron ore) plant.
The coal used in the plant is cleansed of
impurities in coke ovens. Conveyor belts
carry metallics — pellets and sinters — to
the heart of the steel plant, the blast furnace.

The blast furnace is a six-storey tall reactor

where the seemingly magical transformation
of dark iron ore into glowing hot liquid iron
takes place. The ore is charged into the blast
furnace along with fluxes and limestone.
Temperatures in the blast furnace reach up
to 1,5000C and the resulting metallurgical
reaction converts iron oxide into molten iron.
The blast furnace works round the clock.

Molten iron being transferred into a torpedo

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Molten iron being poured into the furnace

The red hot liquid metal produced in the

blast furnace is collected in the hearth
and ‘tapped’ on a near continuous basis
through day and night. The process is
called casting and, typically, the steel
plant does 10-12 casts in a 24-hour cycle.
Tata Steel has eight blast furnaces and six
of these are operational.

Hot metal or molten iron from the blast

furnace is transferred into vessels called
torpedoes and transported on rail tracks
to the LD, or Linz Donawitz (named after
the towns in Austria where the technology
was commercialised), shop. Here the
molten iron is refined into steel using the
‘basic oxygen furnace’ method. Tata Steel
has three LD shops — one dedicated
to making steel for long products
(used mainly in the infrastructure and
construction sectors) and two others
for flat steel products (typically used in
automobiles and appliances).
Liquid steel being tapped into a ladle car

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At the LD shop the process begins with

charging scrap into the furnace, where
temperatures reach 1,700°C. Large
ladles, capable of holding 170 tonnes of
liquid metal, pour the molten iron into the
furnace. A water-cooled lance is lowered
into the furnace to blow in pure oxygen.
Iron ore (as coolant) and burnt lime and
raw dolomite (as flux) are added from the
top. The oxygen removes carbon, silicon,
sulphur and phosphorus content from
molten iron and converts it to steel, an
alloy that is tougher than iron. One ‘heat’
(a cycle of steelmaking) takes 45-50
minutes and produces an average of 158
tonnes of molten steel. 
Liquid steel being tapped into a ladle car

Hot metal handling at the Linz Donawitz shop

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Billets, which later become long-steel

products, being cut into size

The properties required for steel depend

on the end use. And so, from every heat,
a sample of the molten steel is analysed
to see if it meets the requirement. If there
is any variation, a ‘correction blow’ is
ordered. Once perfected to specification,
liquid steel — still aglow at about 1,630-
1,690°C — is tapped into a ladle car
positioned under the furnace. During
tapping, ferro-alloys and aluminium are
Steel wires at the wire mill added directly into the steel ladle for
alloying and deoxidisation.

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The continuous slab caster, from which emerge flat-steel products

This steel goes through further refining,

depending on requirement, at the online
purging station, ladle furnace station or RH
degasser. Ladles with a holding capacity
of 160 tonnes carry the liquid steel to the
continuous caster machines. Here the
liquid steel finally takes solid form and is
shaped into what are called long products Steel sheets at the hot-strip mill
or flat products.

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The long products are processed at the

wire mill to produce wire rods and rebars.
Tata Steel makes a range of long products,
including TMT rebars branded as Tata
Tiscon, and steel wires that sell under the
brand name Tata Wiron.

Flat steel is further processed at the

hot rolling mill or cold rolling mill,
depending on end use. Cold rolling mills
have a continuous galvanising line and
produce the galvanised steel used in the
automotive, engineering and appliances
sectors. Tata Steel’s branded flat steel
products — Shaktee, Galvano and
Steelium — are known for their
world-class quality.

You may not be aware of it, but there just

could be a bit, or more, of Tata’s steel in
your life. ¨

Processed flat products at the cold roll mill Photographs: The Tata Steel archives,
Jamshedpur

Finished products at the tubes division

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