How to Reduce Scale Formation in Steel Reheating Furnaces

Did you know that oxidation during billet reheating can lead to around 1.5% steel loss in many hot rolling mills?

For a steel plant producing 2 million tons annually, that means nearly 30,000 tons of steel lost every year—not to mention the impact on surface quality, yield, and production costs.

Scale formation during reheating is unavoidable, but it can be significantly reduced with the right process control.

What causes scale formation?

Several key factors drive high-temperature oxidation in reheating furnaces:

• Heating temperature – Oxidation accelerates rapidly above 1150 °C
• Furnace residence time – Longer heating increases oxidation loss
• Furnace atmosphere – Excess oxygen dramatically raises oxidation rates
• Billet surface condition – Rough surfaces and contaminants promote scale growth

How steel plants can reduce oxidation

In practice, several improvements can make a significant difference:

• Optimize heating temperature settings while maintaining uniform heating
• Improve burner calibration and air-fuel ratio control
• Enhance billet surface preparation before charging
• Increase production rhythm to shorten billet residence time
• Optimize rolling passes to avoid unnecessary overheating

The impact

Reducing scale formation can deliver multiple benefits:

✔ Higher steel yield
✔ Better surface quality
✔ Lower fuel consumption
✔ Improved production efficiency

In modern hot rolling operations, oxidation control in reheating furnaces is becoming a key lever for improving both quality and cost performance.

How does your plant control scale formation during billet reheating?
Always interested in hearing different approaches from across the steel industry.