Steel Sector Decarbonisation – Why Hydrogen and Renewables Hold the Key

Key Points

• China's steel industry faces multiple challenges such as overcapacity, high carbon emissions, green steel premiums and tariffs. However, with the support of carbon peak and carbon neutrality policies, China's steel industry is gradually moving away from a high-carbon model and entering a new low-carbon era, with both opportunities and challenges.
  
  
• Scrap-based Electric Arc Furnace (EAF) and Hydrogen-based Direct Reduced Iron (H₂DRI - EAF) are the two main low-carbon steel production processes. Green hydrogen and renewable energy (RE) offer a more self-sufficient and scalable decarbonization pathway for China’s steel industry, reducing reliance on external supply chains and avoiding subsidy-driven competition.
  
  
• While waiting for further updates on capacity reduction measures, we recommend prioritizing the development of electric arc furnaces as the cornerstone of steel decarbonization. In addition, it is critical to develop refining policies to improve scrap recycling and revitalize the scrap steel industry. In addition, strengthening hydrogen connectivity and efficiency with the steel industry while promoting regional development through self-production projects will help strengthen the transition to low-carbon steelmaking.

Current status of steel decarbonization in China

In 2024, China's crude steel production remains above 1 billion tons, while consumption falls to 892 million tons, a year-on-year decrease of 5.4%. Therefore, even if steel demand declines, overcapacity still exists. Although both production and consumption may have peaked, carbon intensity remains relatively high due to the dominance of the coal-dependent blast furnace-converter (BF-BOF) production process. At the company level, factors such as green steel premiums and international tariffs are putting pressure on profit margins, which may hinder low-carbon investment, cause financial losses or even more serious challenges, and ultimately slow down the industry's transition to a low-carbon future.

 

To advance China's carbon peak and carbon neutrality goals, China has introduced a series of policies to strengthen the construction of a carbon dual control system. The government has also launched the "Special Action Plan for Energy Conservation and Carbon Reduction in the Steel Industry", setting clear goals for 2025, such as improving energy efficiency, increasing the use of scrap steel, and increasing the proportion of electric furnace steelmaking. During the 2025 Two Sessions, the National Development and Reform Commission listed "continuously regulating crude steel production, promoting capacity reduction and structural adjustment" as the key tasks of the 2025 National Economic and Social Development Plan. In addition, China has explicitly supported hydrogen metallurgy and announced a detailed implementation plan to promote the construction of upstream and downstream demonstration projects in the "green electricity-green hydrogen-pure hydrogen metallurgy" value chain and promote integrated decarbonization of the steel industry.

 

2025 is indeed an important year, as it is the final year of China's 14th Five-Year Plan and a key year for the steel industry's decarbonization transformation, preparing for the release of the 15th Five-Year Plan. At present, steel capacity replacement is still on hold, and the steel industry has just been included in China's national emissions trading system. The steel industry is gradually getting rid of the high-carbon model and entering a new era, a low-carbon era with both opportunities and challenges.

Green hydrogen and renewable energy are decisive advantages for China's steel decarbonization

China's global leadership in green steel production, especially low-carbon hydrogen metallurgy, is due to its significant advantages in green hydrogen and renewable energy.

 

In the context of steel decarbonization, electric arc furnaces are important infrastructure for low-carbon steel production, while scrap steel, renewable energy and green hydrogen are key resources to help steel production get rid of coal-based emissions and achieve a comprehensive low-carbon transformation.

These elements together support two key low-carbon steel manufacturing processes: scrap-based electric arc furnaces (often referred to as "short processes" in China) and hydrogen-based electric arc furnace direct reduced iron (H₂DRI - EAF). These processes can achieve near-zero carbon emissions in steel production.

• Decarburization effect of electric arc furnace: short process and hydrogen direct reduction electric arc furnace

Replacing coal with electricity can significantly reduce emissions. One way is to melt scrap steel, eliminating the coal-intensive ironmaking process. Another is to use hydrogen instead of coal to extract oxygen from iron ore. Emissions fall further if the electricity needed for these processes comes from renewable energy.

Although the Chinese government is implementing policies to guide the steel industry in a more sustainable direction, its EAF capacity remains a relatively low proportion of domestic steel companies.

According to Global Energy Monitor (GEM), China's EAF capacity accounts for about 14% of total steel capacity by January 2024, far below the global average of 31%. In addition, China's EAF capacity utilization rate is relatively low, resulting in EAF steel production accounting for only about 10%, compared to the global average of 28.6%. At the time of writing, China is suspending its steel capacity replacement plan, and the details of the future development of EAF are unclear. However, with the official establishment of the Electric Arc Furnace Steelmaking Branch of the China Iron and Steel Association, EAF is likely to play a greater role in China's low-carbon steel development.

• Resources, production capacity and development of scrap steel, green hydrogen and renewable energy

China still has great potential in scrap steel utilization. In 2023, China consumed about 214 million tons of scrap steel, but only about 30% was used for mini-process steelmaking, with limited decarbonization benefits. In terms of resource distribution and supply and demand dynamics, China's scrap steel is close to a balanced state. However, differences in resource supply and demand between regions have led to the cross-regional flow of scrap steel, increased logistics costs, and to some extent hindered the rapid development of mini-process steelmaking.

In terms of policy, China is supporting the efficient and high-quality use of scrap steel resources, expanding imports of recycled steel, and striving to achieve the goal of 300 million tons of scrap steel use by the end of 2025.

On the other hand, green hydrogen and renewable energy have unique competitive advantages. China's abundant wind and solar resources provide a solid foundation for the growing renewable energy industry, which in turn supports the production of green hydrogen through electrolysis. China currently leads the world in both renewable energy capacity and hydrogen electrolysis installations. Unlike scrap steel, renewable energy and hydrogen production can be scaled up domestically without relying on external markets.

As production expands, the production cost and price of green hydrogen are expected to become more competitive. In addition, both industries benefit from strong policy support. The recently issued "Implementation Plan for Accelerating the Industrial Application of Clean and Low-Carbon Hydrogen Energy" encourages the development of an integrated value chain of "green electricity-green hydrogen-pure hydrogen metallurgy". This initiative not only accelerates the development of green hydrogen and renewable energy, but also strengthens the industrial connection between hydrogen, renewable energy and steel. For example, Zhangjuan Technology Co., Ltd., a subsidiary of Hesteel Group, has begun to move in this direction, using Zhangjiakou's abundant renewable energy resources to build the Yantongshan distributed photovoltaic project. The company also plans to develop green power direct supply, green hydrogen production and green energy storage projects this year.

This marks an important step for Hesteel towards achieving near-zero carbon hydrogen metallurgy using completely green hydrogen, and also enhances China's confidence in the scale-up and commercialization of low-carbon hydrogen metallurgy.

Suggestion

1. Make the electric arc furnace the core of steel decarbonization

Both mini-process steelmaking and hydrogen direct reduction electric arc furnace steelmaking processes rely on electric arc furnaces. Guiding the phased retirement of blast furnace-converter or replacing blast furnace-converter capacity with electric arc furnaces is a practical solution to resolve overcapacity, optimize China's steel production structure and promote carbon emission reduction. Although capacity replacement work is currently suspended, we expect future policies to support electric arc furnaces. We also recommend that steel companies increase the utilization rate of electric arc furnaces to promote production growth and help China achieve its goal of electric arc furnace steel accounting for 15% of total steel production by the end of 2025.

2. Improve the economic feasibility of short processes

One of the main challenges facing the development of mini-steel in China is the limited supply and high cost of scrap steel. As global attention to mini-steel continues to increase, scrap steel may become a strategic resource whose price is affected by fluctuations in supply and demand. In order to improve the economic viability and international competitiveness of mini-steel production in China, we need to establish an efficient scrap steel recycling system, optimize the allocation of scrap steel resources across the country, and reduce logistics costs. We also hope that new policies can provide subsidies or incentives for mini-steel and scrap steel, so that Chinese companies can reduce carbon emissions while maintaining competitiveness.

3. Actively deploy hydrogen direct reduction iron furnaces to maintain China's global leading position in green steel

Green hydrogen and renewable energy are key advantages for China to achieve decarbonization of steel production. Given China's vast territory, it is crucial to effectively integrate green hydrogen and renewable energy with downstream steel companies.

Improving the efficiency of hydrogen storage and transportation, improving the efficiency of renewable energy storage and grid transmission, and establishing long-term green power purchase agreements between renewable energy companies and steel companies will strengthen their connection with the steel industry, maximize carbon emission reduction benefits, and support steel companies to gradually develop diversified innovative low-carbon development models such as "renewable energy + energy storage + green hydrogen".

At the same time, we suggest supporting qualified regions and steel companies to develop green electricity self-production and green hydrogen projects, create an integrated industrial chain demonstration zone of "green electricity-green hydrogen-pure hydrogen metallurgy", and promote regional low-carbon development.

Ensure a stable supply of high-grade iron ore and accelerate the utilization of low-grade ore.

High-grade iron ore (about 67% iron content) is required to produce hydrogen-reduced iron, but China's domestic supply of such ore is limited and it relies heavily on imports. Given the current geopolitical uncertainties and supply chain risks, China must ensure a stable supply of iron ore and diversify its import sources. In addition, investment in low-grade ore utilization technology will reduce dependence on imports, improve resource efficiency, and enhance production autonomy.

In summary, both the mini-process and high-pressure direct-fired electric arc furnace low-carbon steelmaking methods can achieve significant decarbonization. China has provided varying degrees of incentives and guidance for the four key elements supporting these processes - electric arc furnaces, scrap steel, green hydrogen and renewable energy. Given China's current policy and market environment, electric arc furnaces will become the mainstream method for decarbonizing steel in the future. At the same time, the advantages of green hydrogen and renewable energy in resource availability and policy support make them safer and more cost-effective green steel production solutions than the mini-process in the long run. This puts China in a leading position in the global green steel race.

Five actions to improve the sustainability of steel

Steel is one of the world’s most sustainable materials, but decarbonizing remains a challenge.

In brief

• Steelmaking currently contributes around 8% of the world’s total carbon emissions, making decarbonization a global priority.
• Technological advances have helped reduce emissions but there are five actions that can accelerate a sustainable transition.
• A collaborative approach from industry, government and consumers can build a commercially viable green steel market.

Steel is critical to continued economic development and the backbone of global sustainable initiatives, including the energy transition. But the steel industry is also one of the world’s most energy-intensive, accounting for around 8% of global carbon dioxide emissions.

For steelmakers, reducing these emissions is critical as the global decarbonization agenda accelerates. Steelmakers that move now to improve the sustainability of operations can get ahead of evolving carbon regulations and capitalize on environmental, social and governance (ESG) metrics to gain a competitive edge.

How should steelmakers steer the transition

Over the past 50 years, advances in technology and a move from traditional blast furnaces (BFs) toward the electric arc furnace (EAF) have reduced energy use in steel production by 60%. “The continued move to EAF will drive down emissions further, but creating a genuinely sustainable industry will require broader, bolder measures from all players across the steel value chain,” said Bob Stall, EY US Mining & Metals Leader.

For steelmakers, five key actions can help guide the sustainable transition:

• Assess and adopt clean technologies, promoting a balance of risk, capital cost and quality
• Increase production of sustainable steel to capitalize on growing demand
• Improve ESG performance to meet shareholder expectations
• Embrace digitization to unlock value
• Collaborate with all stakeholders to accelerate the transition to improve output quality

Assess and adopt clean technologies

Combining short-term commercial imperatives with long-term value creation requires balancing risk, cost, quality and decarbonization. Aligning investments with cyclical gains can mitigate financial risks, as higher initial capital costs are likely to be offset by the long-term benefits of more sustainable operations and improved ESG performance.

Steelmakers may consider adopting some of these emerging technologies to reduce emissions:

1. Carbon capture

Top gas recycling can recycle up to 90% of the exhaust gas from BFs, reusing it for combustion with the remaining highly CO2-concentrated 10% able to be stored or used.2 Determining whether carbon capture is suitable may depend on overall operating costs, with technology costs still high at this stage of maturity.

2. Innovations in product mix

Moving to scrap-based EAF production will reduce emissions, but each steelmaker will need to decide whether and how to transition based on the affordability and availability of scrap and the desired quality of the end product.

A comparison of emerging and new technology production methods for greener steel

3. Hydrogen

Use of green hydrogen (generated by renewables) with direct reduced iron (DRI) and EAF is likely to be the cleanest alternative for steelmakers in the future,3 although it will be some time before hydrogen is economically feasible and scalable.

4. Alternative smelting reduction processes

Some newer commercialized smelting reduction processes can offer better emission control compared with integrated plants, but their economic viability depends on overall power consumption and use of export gases.

Increase production of sustainable steel

As companies face more pressure to reduce scope 3 emissions, demand for low-carbon supplies, including steel, is growing. In particular, automakers which use 12% of the world’s steel use, are accelerating decarbonization initiatives and seeking cleaner inputs.4 Government incentives are likely to boost demand further.

Steelmakers that produce more green products can capitalize on this demand. We already see some dominant players offering certified green steel products in a trend set to increase.

Improve ESG performance

Investors are seeking more sustainable portfolios, demanding greater ESG compliance and performance from potential investment targets. At the same time, pressure from government to decarbonize is increasing, with many countries enforcing carbon tax regimes and emission trading systems (ETSs).

Improving ESG metrics will reap benefits for steelmakers beyond compliance with regulations and stakeholder expectations. “Companies with a better ESG performance can secure project financing at a lower cost, enhance resources management, reduce operational risk and increase resiliency against future changes,” said Saurabh Bhatnagar, EY India National Mining & Metals Consulting Leader; Partner, Ernst & Young LLP. Some steelmakers are including the impact of carbon emissions when assessing the profitability of capital investments. Adopting shadow internal carbon prices can help identify sustainability inefficiencies and the potential impact of a low-carbon economy on costs.

Embrace digitization to unlock value

Many steelmakers are already digital leaders, adopting technology to improve defect recognition, process safety and quality assurance. But there is a potential to make greater use of digitization to quantify, monitor, record and assess processes to enhance sustainability performance and reporting.

Digital solutions can also help improve productivity by optimizing energy consumption, minimizing waste and controlling emissions. And blockchain offers the potential to verify the sustainability quotient of steel value chains, giving end users reliable data to assess their net carbon impact. It can also help create more agile supply chains, while cloud computing can allow central command and control centers to oversee geographically dispersed mine-to-metal value chains.  

Collaborate with all stakeholders to accelerate the transition

Decisions made around sustainability initiatives cannot be based purely on financial costs to the business. Instead, steelmakers must act with all stakeholders in mind and be prepared to make a balanced trade-off between industry, end consumers and the environment. Aligning stakeholders will be critical to quicken the pace of change needed and to enable the collaboration required to co-develop feasible solutions to complex challenges.

Building the future of green steel

The steel industry’s transition to greener steel will not be uniform across regions. Steel producers in Western regions and countries already investing in improving sustainability are likely to see a more rapid adoption of low-carbon technologies compared with steel producers in China and India, where the combination of newer capital assets and cost pressures will force a more gradual transition.

Even in countries where progress will be slower, steelmakers should make incremental investments in process improvements to decrease energy intensity, reduce carbon emissions, increase material efficiency and promote the circular economy. Given the relatively large carbon footprint of steel production, even small steps will make a big difference in moving the industry closer to carbon neutrality.

Making this shift will require a staged digital road map to realize the potential of new technologies and achieve economies of scale, while improving sustainability across the steel value chain. And it will require steelmakers to join with a broad range of stakeholders, including governments, the United Nations, academia, communities and the World Steel Association, to build a greener steel industry.

Steel is one of the world’s most sustainable materials — permanent, forever reusable and the most recycled substance on the planet. Building a more sustainable production process is a long-term investment that will yield enormous environmental benefits over the full life cycle of green steel.

One stop service for steel industry

6 Steps of the Steel Manufacturing Process

Steel is known for being lightweight but strong, making it suitable for a variety of industries and applications. Next to plastic and paper, steel is one of the most common materials seen in products used in our everyday lives.

In the construction industry, steel is used in the creation of buildings and other structures for strength. Manufacturing processes, such as for cars, airplanes, and kitchen appliances, also rely on steel for production. Last but not least, steel is imperative for communication as it is used in the creation of transmission and cell phone towers.

The steel manufacturing process can be divided into six steps: Making the iron, primary steelmaking, secondary steelmaking, casting, primary forming, and secondary forming.

Step 1: Making the Iron

Steel is a metal alloy made of iron and carbon. Thus, the steel manufacturing process starts by making iron. To do this, limestone, coke, and iron ore are combined and put into a blast furnace. The elements are melted together to create a hot metal known as molten iron.

Step 2: Primary Steelmaking

The second step of the steel manufacturing process can be completed with two different pieces of equipment: a basic oxygen furnace and an electric arc furnace. With a basic oxygen furnace, the molten metal produced in step 1 is infused with scrap steel. Then, oxygen is forced through the furnace to remove the impurities in the molten iron. With an electric arc furnace, as the name suggests, electricity is forced through the furnace to purify the iron. The completion of step 2 results in raw steel.

Step 3: Secondary Steelmaking

Just like there are different grades and families of stainless steel, there are also different types of regular steel. The different grades are determined by the elements that remain in the metal at the completion of the manufacturing process. Secondary steelmaking refines the composition of the steel to create the desired grade. This is done with different techniques such as stirring and ladle injections.

Step 4: Casting

During the fourth step of steel manufacturing, molten iron is cast into molds for cooling. This process starts to set the shape of the steel and causes a thin, hard shell to form. The strands of the shell are malleable and can be worked into the desired shape of flat sheets, beams, wires, or thin strips.

Step 5: Primary Forming

Primary forming continues the shaping process. A hot roller is used to fine-tune the casting. The steel is molded into the desired shape and surface finish. Some examples include bloom, billet, and slab.

Step 6: Secondary Forming

The final step of the steel manufacturing process creates the final shape and properties of the steel. Secondary forming is accomplished with different methods such as shaping (cold rolling methods), machining (drilling), joining (welding), coating, heat treatment, and surface treatment. At the completion of step 6, the steel is fully shaped, formed, and ready for use and processing in various applications.

The harsh environment and extreme temperatures encountered in steel mills during the steel manufacturing process require high-quality equipment built to last. LMM GROUP offers a variety of products suitable for steel mills.

How Steel is Made, Step by Step

Chances are, you've already used steel in several ways today - from the car you drove in to work to the knife and fork you used at dinner. Steel is all around us and the world would look very different without it, but most of us don't really know how it's made.

Before We Start...

Steel production is a complex process that can vary based on the type of steel and the techniques used. This guide will be focusing on the most common method, basic oxygen steelmaking, but keep in mind that not all steel is processed this way - some are refined using electric arc furnaces or other methods.

Now, let's walk through how the typical process works.

1. Raw Material Extraction

The steel-making process begins with gathering the essential raw materials: iron ore, coal, and limestone.

Iron Ore: This is the main source of iron, the key element in steel. The most commonly used types are hematite and magnetite.

Coking Coal: Coking coal is used to produce the intense heat needed to reduce the iron ore into a usable form.

Limestone: Limestone removes impurities such as silica, sulphur, and phosphorus during the process.

Alloying elements like magnesium or nickel may also be gathered for use later in the refining process.

These materials are typically mined from large deposits and transported to steel mills, where the transformation into steel begins.

2. Coke Making

The next step is turning coal into coke (no, not the drink). This involves heating coal in a low-oxygen environment, usually in a coke oven, to remove volatile compounds. This leaves behind coke, a carbon-rich fuel that burns hotter and cleaner than regular coal.
Coke is crucial because it provides the intense heat needed in the blast furnace, where the iron ore will be melted down.

3. Blast Furnace

Once the coke is ready, the next step is to produce molten iron in a blast furnace - a massive structure that can reach 100 to 200 feet tall. Here's how the process works:

Iron ore, coke, and limestone are layered inside the furnace, which is lined with heat-resistant bricks.

Hot air around 1,500--2,200°C is blasted into the furnace from the bottom. This extreme heat ignites the coke to create carbon monoxide gas, which reacts with the iron ore, reducing it to molten iron.

As the iron ore melts, impurities like silica form a liquid slag that floats on top of the molten iron. The purified iron, now in liquid form, sinks to the bottom of the furnace and is tapped off.

This molten iron, known as pig iron, still contains a high level of carbon and impurities, which makes it brittle. It needs to go through a refining process to turn it into steel.

Fun fact: Pig iron got its name from the way the moulds were arranged for casting. The moulds were set up in a pattern that resembled a mother pig with her piglets. The larger mould, where the molten iron was poured, was called the "sow," and the smaller ingots that flowed from it were called "pigs"!

4. Basic Oxygen Steelmaking (BOS)

The pig iron from the blast furnace is then taken to a basic oxygen furnace to be refined into steel. This process lowers the carbon content and removes impurities, making the iron stronger and more versatile.

Molten pig iron is poured into the furnace, and pure oxygen is blown in at high pressure. The oxygen reacts with the carbon in the pig iron, creating carbon dioxide and reducing the carbon content.

Fluxes like limestone are added to help remove impurities. As the oxygen and fluxes react with the carbon and other impurities, they form slag, which is then removed.

The amount of oxygen injected, and the timing of the process are carefully adjusted to make sure the carbon content reaches the desired level for the specific type of steel being produced (e.g. 0.3% for mild steel), while preserving the steel's other essential properties.

At this stage, alloying elements like manganese, chromium, or nickel can be added to give the steel specific properties, such as increased strength or corrosion resistance. This creates different types of steel, with stainless steel being one of the most well-known.

The result is high-quality liquid steel with a much lower carbon content than the original pig iron.

5. Casting

Once refined, the molten steel is ready to be cast. The steel is poured into moulds to form slabs, billets, or blooms, depending on the desired shape.

Most modern steel plants use a method called continuous casting. In this process, the molten steel is continuously poured into a water-cooled mould, where it solidifies as it moves downward. This produces long strands of steel that are cut to the needed length. Steel might still be cast into large ingots in some cases, but this method is less common today.

6. Forming and Shaping

After the steel has solidified, it goes through additional shaping to create the final product. This is usually done through hot or cold rolling:

Hot Rolling: The steel is heated above its recrystallisation temperature and passed through large rollers to reach the desired thickness. This method is used for products like steel sheets, beams, and rails.

Cold Rolling: For some applications, the steel is rolled at room temperature. This gives the steel a smoother surface and more precise dimensions, making it ideal for products that require a high-quality finish.

7. Finishing Processes

The final step in the actual steel-making process is a series of finishing treatments that prepare the steel for use in construction, manufacturing, and other industries. These processes include:

Soaking the steel in acid (known as 'pickling') to remove surface impurities like rust or scale.

Galvanisation, which involves coating the steel with zinc to protect it from rusting.

Heat-treating the steel to improve its strength, ductility, or toughness.

Adding a protective coating or a colourful painted finish.

Cutting to meet certain specifications.

8. Quality Control and Testing

Before steel products are shipped out, they go through strict quality control tests to make sure they meet the necessary mechanical properties, chemical composition, and dimensional tolerances. Common tests include:

Tensile testing to measure the steel's strength.

Hardness testing to check its resistance to indentation.

Ultrasonic testing to detect any internal flaws or cracks.

Once the steel passes these tests and meets the standards, it's ready to be used in a wide range of products - from tools and machinery to vehicle frames, furniture, medical equipment, and just about anything else you can imagine!

Ladle Furnace Essentials: Streamlined Steel Refining Process

 

The Ladle Furnace: Simplifying Steel Refining

The ladle furnace (LF), a secondary refining system, is indispensable in modern steel production. Positioned between primary steelmaking and continuous casting, this equipment enhances steel quality through three core functions: precise temperature control, targeted impurity removal, and exact alloy adjustments.

Three Pillars of LF Efficiency

1. Dual-Stage Impurity Removal

The LF combines deoxidation (oxygen removal) and desulfurization (sulfur reduction) through:

• Direct aluminum injection for rapid oxygen binding


• High-basicity slag (CaO/SiO₂ ≥2.5) that absorbs sulfur


• Argon gas stirring to accelerate reactions

This tandem approach achieves sulfur levels below 0.002% in specialty steels.

2. White Slag Optimization

The LF's signature low-oxidation slag system:

1. Reduces FeO+MnO content below 4%


2. Maintains a reducing atmosphere via argon shrouding


3. Enables 90% inclusion removal efficiency

3. Precision Temperature Control

Electric arc heating allows:

• 5°C/minute heating rates


• ±3°C temperature uniformity


• Optimal casting conditions

Why Argon Stirring Matters

Argon gas performs critical roles:

• Homogenizes steel chemistry in under 5 minutes


• Prevents slag foaming during heating


• Removes oversized inclusions (>20μm)

LF in Numbers

Key operational benchmarks:

• Refining time: 25-45 minutes per heat


• Argon consumption: 0.4-1.2 Nm³/ton


• Alloy recovery rates: 92-98%

ladle furnace refining basics、LF desulfurization techniques、steel temperature control in LF

Magnesita Refractories: Efficient Tundish Lining Solutions

 Magnesita Refractories: Smart Installation for Durable Tundish Linings

Core Installation Guidelines

Magnesita refractories combine organic/inorganic binders to create high-performance linings. Critical parameters include:

• Permanent layer temp: <100°C (ideal: ambient)
• Working layer thickness: 40-50mm (bottom), 45-60mm (walls)
• Minimum 55mm at slag line

3-Step Installation Process

1. Preparation & Base Layer

Install impact pads with ramming mix, spread magnesia dry vibratables evenly, and position forming molds with 45-60mm clearance from permanent walls.

2. Vibration & Curing

Layer material in 3-5min vibration cycles. Cure at 200-250°C for 60-90min, then cool below 100°C before demolding.

3. Final Assembly

Inspect for defects (>2mm cracks require repair), install flow control components, and backfill joints with matching material.

Optimized Baking Protocol

Maximize magnesita refractories' performance with:

• 30min ramp to 800°C
• 70min hold at 1100°C
• Total time: 70-180min

Key Advantages

Magnesia-based linings deliver:

• 12h+ operational lifespan
• 20% lower steel inclusion rates
• Reduced thermal shock risks

Pro Maintenance Tips

Extend magnesita refractory life with:

1. Post-cast laser wear scanning
2. Preventive repairs at 8h intervals
3. Controlled cooling between heats

Magnesita Refractories: Smart Installation for Durable Tundish Linings

Core Installation Guidelines

Magnesita refractories combine organic/inorganic binders to create high-performance linings. Critical parameters include:

• Permanent layer temp: <100 ambient="" ideal:="" li="">
• Working layer thickness: 40-50mm (bottom), 45-60mm (walls)
• Minimum 55mm at slag line

3-Step Installation Process

1. Preparation & Base Layer

Install impact pads with ramming mix, spread magnesia dry vibratables evenly, and position forming molds with 45-60mm clearance from permanent walls.

2. Vibration & Curing

Layer material in 3-5min vibration cycles. Cure at 200-250°C for 60-90min, then cool below 100°C before demolding.

3. Final Assembly

Inspect for defects (>2mm cracks require repair), install flow control components, and backfill joints with matching material.

Optimized Baking Protocol

Maximize magnesita refractories' performance with:

• 30min ramp to 800°C
• 70min hold at 1100°C
• Total time: 70-180min

Key Advantages

Magnesia-based linings deliver:

• 12h+ operational lifespan
• 20% lower steel inclusion rates
• Reduced thermal shock risks

Pro Maintenance Tips

Extend magnesita refractory life with:

1. Post-cast laser wear scanning
2. Preventive repairs at 8h intervals
3. Controlled cooling between heats

Key Factors Driving Magnesium Bricks Costs | Industry Analysis

 

What Determines Magnesium Bricks Pricing? 5 Critical Factors

1. Raw Material Costs: The Core Driver

Magnesia Quality Matters

High-purity fused magnesia (MgO ≥95%) costs 25% more than standard grades but delivers better thermal stability. Supply chain disruptions in major producing regions like China can cause price spikes exceeding 30%.

Graphite Market Pressures

Flake graphite (C ≥90%) enhances thermal shock resistance but competes with battery manufacturers. A 15% graphite price increase typically raises magnesium bricks costs by 7–9%.

2. Production Technology Impacts

Advanced Manufacturing

Isostatic pressing creates bricks with 98% density uniformity, enabling 20–25% price premiums. Automated mixing systems reduce material waste by 12% but require $1.5M+ investments.

Energy Efficiency

Modern kilns with AI-controlled combustion cut energy costs by 30%, saving $15–20 per ton. These technologies help offset rising raw material expenses.

3. Market Demand Fluctuations

Global steel production (1.95B tons in 2023) drives 65% of magnesium bricks demand. China’s green steel initiatives could boost premium brick requirements by 35% by 2030. Oversupply scenarios during industry downturns trigger price drops up to 18%.

4. Quality Specifications

Key Performance Metrics

• Thermal cycles: 25+ (1100°C ⇄ water)
• Compressive strength: ≥45 MPa
• Erosion resistance: ≤1.5 mm/hour

Nuclear-grade magnesium bricks cost 250% more than industrial grades due to strict certification requirements.

5. Strategic Purchasing Tips

Supplier Evaluation

Prioritize vendors offering:

• Third-party quality certifications (ISO 9001)
• Technical support teams
• 60–90 day inventory buffers

Cost Optimization

Implement JIT purchasing with 45-day safety stock. Predictive analytics can reduce inventory costs by 18% while maintaining 97% supply reliability.