The Industrial Revolution changed the world immensely, and steel played a big part in it. Steel has existed since the 14th century, and technological innovations have made it better and more cost-effective. There is hardly any part of daily life that does not involve steel, from our homes and buildings to the component parts of our vehicles and devices.
However, there is still room for improvement. Modern steel manufacturing is evolving as new designs and advanced technology shape the industry. The trend is for development to reduce the environmental impact of steel manufacturing and increase client satisfaction.
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Steel Manufacturing 101
Steel manufacturers use one of two primary methods: blast furnace and electric arc furnace (EAF). The blast furnace has been around since the 14th century to process iron to extract steel using coke. Coke is concentrated carbon extracted from coal, producing enough energy to melt iron.
The first iterations of the blast furnace could produce a ton of steel daily. While modern blast furnaces can make more and typically use natural gas instead of coke, the process is the same.
EAFs, on the other hand, became a thing much later, in the late 19th century. The process passes an electric current through scrap steel to produce liquid steel. Manufacturers use the EAF method to create about 70 percent of US steel. The EAF method is more efficient and has a smaller carbon footprint than the blast furnace method.
Some manufacturers use the EAF method in a mini mill concept to control the scale of operation, electrical consumption, and product range. Using alternative materials such as direct reduced iron (DRI) pellets produces steel with a higher concentration of iron than scrap metal.
Challenges
Steel manufacturing is a big business, but it does not exist in a bubble like any industry. Aside from production issues, manufacturers also deal with complex labor, legal, and logistics matters. Steel production is a highly regulated industry regarding worker safety because it is a dangerous occupation.
Supply and delivery chains are also intricate, as legal requirements vary when dealing with international suppliers and clients. Failing to deal with these issues effectively can result in lower profits and higher risks of non-compliance and liability.
Advanced Technology
Advanced technology can and does address many of these issues through robotics, computer models, artificial intelligence, and data analytics. Robots, for instance, have reduced the human resources needed to monitor and manage steel production dramatically. The use of remote-controlled machines has also improved safety on the production floor.
Robots
The rise in the use of industrial robots in steel manufacturing arose primarily to keep workers safe. Working near furnaces and handling liquid metal have a high potential for injury and death. Even small mistakes can lead to catastrophic consequences.
However, manufacturers noted that using robots also improved the quality and affordability of their products. Eliminating human errors in repetitive work and reducing the number of human workers led to significant savings. Additionally, the increase in efficiency also shortened the production and delivery time.
Automation
Steel manufacturers juggle numerous tasks, and automation can help them from dropping any of them. In one survey of steelmakers, they identified areas where they believed automation could help.
Source: Crowe
As you can see, most want automation to improve operations, production, and supply chain management. The next big issue for manufacturers is quality and reliability.
Automating steel production helps with maintaining quality while keeping workers safe. Before automation, workers had to do steel sampling and testing, a dangerous practice carried out under extremely high temperatures. Machines have now taken over quality assurance, monitoring oxygen and temperature levels regularly without the need for human personnel.
Computer 3D modeling and printing have also allowed manufacturers to offer clients affordable product options, such as DIY kits. The technology enables designers to produce kits with precise measurements based on specific requirements that would take significant resources to make manually. Clients can benefit from custom-building equipment sheds with a purpose-driven design without diving too deep into their pockets.
Additionally, sensors have enabled manufacturers to gather data about their process to pinpoint issues and predict product quality. Closed-loop systems using machine learning can help operators implement automated adjustments in manufacturing to improve efficiency and product quality. However, these systems require human operators to oversee the processes. Technological advancements have simply allowed steelworkers to work in a safer environment.
The entire steelmaking process has become highly automated, making producers more precise about their decisions. Additionally, automated systems are innately accurate, leading to less material waste. The controlled and consistent application of raw materials reduces scrap generation, conserving resources and easing the need for energy-intensive recycling processes.
Using automation and robotics in steelmaking helps make the process more sustainable. Developers design automated systems to maximize available resources, reducing power usage and carbon footprint.
Environmental technology
Producing steel requires high energy use, primarily using fossil fuel sources. However, the industry has been relentless in its pursuit to reduce its carbon footprint through research and development. It is working on developing zero or low-emission iron ore extraction methods, including using solar power. While these technologies are for the future, the US steel industry already consumes less energy than other countries. It has also reduced its CO2 emissions by 37 percent since 1990.
Aside from the potential long-term benefits of environmental protection, steelmakers investing in green technology score brownie points with clients. For instance, automakers want greener steel to meet climate targets and cater to customer demand for sustainable products.
Steelmakers subscribing to sustainable practices such as EAF, solar power, recycling, and DRI will likely close more deals. It has already led to some notable partnerships. One example is a memorandum of understanding between Rio Tinto and Nippon Steel to develop a low-carbon emission steel value chain.
The Tech Future of Steel
Steel is already a technological marvel resulting from centuries of out-of-the-box thinking and innovations. The arrival of advanced technology such as robotics, artificial intelligence, and computer modeling significantly impacts all aspects of our lives.
However, the steel industry and its workers benefit fundamentally, from increasing worker safety to decreasing their carbon footprint. The tech trends in steel manufacturing signal the march to better, more affordable steel products with less environmental impact. That will provide consumers with sustainable, cost-effective, and high-quality products.
Image by Arnoldius via Wikimedia Commons
