FM Global

Property Loss Prevention Data Sheets 7-25

October 2013
Page 1 of 18

MOLTEN STEEL PRODUCTION

Table of Contents
Page

1.0 SCOPE ..................................................................................................................................................... 2

1.1 Changes ............................................................................................................................................ 2
1.2 Superseded Information .................................................................................................................... 2
2.0 LOSS PREVENTION RECOMMENDATIONS ......................................................................................... 2
2.1 Construction and Location ................................................................................................................. 2
2.1.1 General .................................................................................................................................... 2
2.1.2 Blast Furnaces ........................................................................................................................ 2
2.1.3 Arc Furnaces ........................................................................................................................... 3
2.1.4 Basic Oxygen Furnaces .......................................................................................................... 3
2.2 Occupancy ......................................................................................................................................... 3
2.2.1 Arc Furnaces ........................................................................................................................... 3
2.2.2 Basic Oxygen Furnace ............................................................................................................ 4
2.2.3 Casting .................................................................................................................................... 4
2.3 Protection ........................................................................................................................................... 4
2.3.1 General .................................................................................................................................... 4
2.3.2 Arc Furnaces ........................................................................................................................... 4
2.3.3 Casting .................................................................................................................................... 4
2.4 Equipment and Processes ............................................................................................................... 5
2.4.1 Blast Furnaces ....................................................................................................................... 5
2.4.2 Arc Furnaces ........................................................................................................................... 6
2.4.3 Basic Oxygen Furnaces .......................................................................................................... 7
2.4.4 Casting .................................................................................................................................... 7
2.5 Operation and Maintenance ............................................................................................................. 8
2.5.1 Arc Furnaces ........................................................................................................................... 8
2.5.2 Basic Oxygen Furnaces .......................................................................................................... 8
2.5.3 Casting .................................................................................................................................... 9
2.6 Human Factor ................................................................................................................................... 9
2.7 Contingency Planning ...................................................................................................................... 10
2.8 Electrical .......................................................................................................................................... 10
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 10
3.1 General ............................................................................................................................................ 10
3.1.1 Blast Furnace (BF) ................................................................................................................ 12
3.1.2 Direct Reduction Iron (DRI) ................................................................................................... 12
3.1.3 Electric Arc Furnace (EAF) .................................................................................................... 12
3.1.4 Basic Oxygen Furnace (BOF) ............................................................................................... 13
3.1.5 Steel Refining Process .......................................................................................................... 13
3.1.6 Casting .................................................................................................................................. 13
4.0 REFERENCES ....................................................................................................................................... 16
4.1 FM Global ........................................................................................................................................ 16
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 17
APPENDIX B DOCUMENT REVISION HISTORY ...................................................................................... 17
APPENDIX C BIBLIOGRAPHY ................................................................................................................... 18

List of Figures
Fig. 1. Process flows for integrated steel mills and mini mills (courtesy World Steel Association) ............ 11
Fig. 2. Basic oxygen furnace components. ................................................................................................. 14
Fig. 3. Cast steel products via ingots .......................................................................................................... 15
Fig. 4. Continuous Caster ............................................................................................................................ 16

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7-25 Molten Steel Production
Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet covers the production of molten iron and steel, including ingot and continuous casting of
slab, billet, and bloom products. Also covered are the production of iron via a blast furnace, and the production
of steel from raw iron in a basic oxygen furnace or from recycled scrap via an electric arc furnace.
This data sheet does not cover the production of raw materials for making iron, such as coke and coke oven
processes. Direct iron reduction is not covered in this data sheet, either, because the process has no molten
phases (there is a brief description of the process in Section 3.0, however, because this process is not
currently covered in any other FM Global data sheet).
Refer to Data Sheet 7-21, Rolling Mills, for guidance on hot and cold rolling of steel products. Refer to Data
Sheet 7-104, Metal Treatment Processes, for guidance on steel pickling operations and steel coating
operations. For more information on the manufacture of ferroalloys, refer to Data Sheet 7-33, High
Temperature Molten Materials.

1.1 Changes
October 2013. Removed recommendation 2.4.1.2 on top gas monitoring on blast furnaces as it was technically
invalid.

1.2 Superseded Information

Data Sheet 5-16, Arc Furnace Transformers, has been made obsolete. The information on arc furnace
transformers in steel occupancies has been put into this data sheet. The remaining information from Data
Sheet 5-16 is covered in Data Sheet 5-4, Transformers.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Construction and Location

2.1.1 General
2.1.1.1 Use high-grade refractory in the construction and relining of all molten metal vessels, such as the
blast furnace, the arc furnace, basic oxygen furnace, and ladles.
2.1.1.2 Locate control rooms and stations so they are not exposed to molten metal spills. If exposure cannot
be avoided, provide protection for these areas.
2.1.1.3 Route all electrical cables and equipment for monitoring and operating critical equipment and auxiliary
equipment away from molten metal exposures. If exposure cannot be avoided, provide heat shielding
between potential molten metal spill areas and the electrical cables and equipment.

2.1.2 Blast Furnaces

2.1.2.1 Protect all structural steel, including major supporting steel for the furnace and casting floor, from
molten metal breakout and other extreme temperature exposures (e.g., super-heated air from furnace
exhaust). The use of masonry covering on structural elements is appropriate.
2.1.2.2 Protect all support equipment (mud guns, tap drills, blowers, tuyeres, tanks, and pumps) and their
foundations from molten metal exposure.
2.1.2.3 Provide sloped floors and drainage around and about the furnace to keep water accumulation from
lying in areas subject to molten metal spills.
2.1.2.4 Locate below-grade storm sewage and drainage openings so that molten metal spills cannot enter
the system.
2.1.2.5 Locate bag houses outside, with explosion venting directed away from the building. Refer to Data
Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosion and Fire, for further guidance.

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2.1.3 Arc Furnaces

2.1.3.1 Locate each arc furnace transformer in a separate room with the following construction and fire rating.
A. If an FM Approved transformer fluid is used, provide one of the following:
1. One-hour fire-rated construction if no automatic sprinkler protection is provided, or
2. Noncombustible construction if automatic fire protection is provided in accordance with Data Sheet
5-4, Transformers.
B. If an FM Approved transformer fluid is not used, provide one of the following:
1. Three-hour fire-rated construction if no automatic sprinkler protection is provided; provide protection
for all exposed structural steel within the room, or
2. One-hour fire-rated construction if automatic fire protection is provided in accordance with Data Sheet
5-4.
2.1.3.2 Locate the furnace control panel outside the transformer room.
2.1.3.3 Install a 1-hour fire-rated, liquid-tight subdivision to isolate any transformer control panels and circuit
breakers or other critical equipment from exposure to an oil fire originating in the transformer room.
2.1.3.4 Provide liquid spill containment and emergency drainage for the transformer room in accordance
with Data Sheet 7-83, Drainage and Containment for Ignitable Liquids. In addition, provide the following:
A. Use blank, liquid-tight walls sealed to the floor.
B. If door openings must be made in interior walls, provide sills above the level of the minimum curb height
specified in Data Sheet 7-83.
An alternative to providing emergency drainage to remove spilled transformer fluid from the room is to protect
the room with automatic water mist or foam-water sprinklers per Data Sheet 5-4.
2.1.3.5 Arrange wall and floor openings to be normally closed, with FM Approved fire doors and/or fire shutters
having the same fire rating as the rest of the room.
2.1.3.6 Arrange louvers and shutters for automatic closing.
2.1.3.7 Close all penetrations through fire-rated construction in transformer rooms, including where
conductors and secondary bus bars pass through walls and floors of the roof. Use FM Approved fire stops,
noncombustible fillers, covers, or doors with a minimum of one-hour fire resistance.
2.1.3.8 Close openings around the secondary bus bar and any other small openings in the vault walls as
tightly as possible with noncombustible fillers, covers, or doors (whichever is most suitable), having a minimum
one-hour fire resistance.
2.1.3.9 Locate bag houses outside, with explosion venting directed away from the building. Refer to Data
Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosion and Fire, for further guidance.

2.1.4 Basic Oxygen Furnaces

2.1.4.1 Locate bag houses outside, with explosion venting directed away from the building. Refer to Data
Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosion and Fire, for further guidance.

2.2 Occupancy

2.2.1 Arc Furnaces

2.2.1.1 Provide radioactive detection for all scrap metal in accordance with Data Sheet 7-33, High-
Temperature Molten Materials.
2.2.1.2 If scrap steel is stored uncovered outside, develop a procedure for drying the scrap steel prior to it
entering the arc furnace (e.g., scrap pre-heaters). If the facility is located in a cold climate, develop a procedure
that will address the possibility of ice collecting within the compacted scrap steel.
2.2.1.3 If oil circuit breakers are present on arc furnace installations, do the following:

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7-25 Molten Steel Production
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A. Extend the vent pipe on an oil breaker outside the transformer room to a safe location, and
B. Inspect oil breakers weekly. If switch service is severe, inspections twice a week may be necessary.
2.2.1.4 Use air circuit breakers, air interrupters, or vacuum switches when replacing existing oil circuit
breakers or for new installations on arc furnace circuits.

2.2.2 Basic Oxygen Furnace

2.2.2.1 Provide radioactive detection for all scrap metal in accordance with Data Sheet 7-33, High-
Temperature Molten Materials.
2.2.2.2 If scrap steel is stored uncovered outside, develop a procedure for drying the scrap steel prior to it
entering the basic oxygen furnace (e.g., scrap pre-heaters). If the facility is located in a cold climate, develop
a procedure that will address the possibility of ice collecting within the compacted scrap steel.

2.2.3 Casting
2.2.3.1 Provide an alternate means of turning the turret in the event of power loss, or provide a specially
designed trough that will divert molten metal breakouts to an emergency holding ladle beneath the casting
floor.
2.2.3.2 Provide emergency containment for a molten metal breakout involving the tundish.
2.2.3.3 Provide a backup cooling water system to ensure reliability. Provide an elevated gravity tank dedicated
to emergency cooling water only for continuous casters. In addition, do the following:
A. Lock open the control valve on the discharge side of the tank.
B. Conduct visual inspections of the control valves on the discharge side of the tank to ensure it remains
locked in the open position. Keep records of the inspections.
C. Provide a low-level alarm on the tank.

2.3 Protection

2.3.1 General
2.3.1.1 For electrical cable runs near molten material, provide heat detection connected to a constantly
attended location.
2.3.1.2 Provide smoke detection in all electrical control rooms and pulpits.
2.3.1.3 Protect under-floor cables in accordance with Data Sheet 5-31, Cables and Bus Bars.
2.3.1.4 Protect bag houses in accordance with Data Sheet 7-76, Prevention and Mitigation of Combustible
Dust Explosions and Fire.
2.3.1.5 Protect cooling towers in accordance with Data Sheet 1-6, Cooling Towers.
2.3.1.6 Provide sprinkler protection in accordance with Data Sheet 7-98, Hydraulics, for all hydraulic oil
systems associated with a continuous caster. An alternative to sprinkler protection is to use an FM Approved
industrial fluid.
2.3.1.7 Protect steam-drive turbo blowers in accordance with Data Sheet 7-101, Fire Protection for Steam
Turbines and Electric Generators.

2.3.2 Arc Furnaces

2.3.2.1 Protect arc furnace transformers and transformers for the ladle refining stations in accordance with
Data Sheet 5-4, Transformers.

2.3.3 Casting
2.3.3.1 Provide automatic sprinkler protection over lubricating oil or grease system storage tanks and pumps
in accordance with Data Sheet 7-32, Ignitable Liquid Operations.

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2.4 Equipment and Processes

2.4.1 Blast Furnaces

2.4.1.1 Provide cooling water monitoring that includes leak detection, high and low temperature, high and
low air flow, and arrange it to alarm to a constantly monitored location.
2.4.1.2 Provide refractory thickness monitoring, particularly in areas where gunnite has been applied.
2.4.1.3 Perform predictive wear analysis of the furnace using, at a minimum, the following information:
A. Erosion, based on burden material and size
B. Chemical, based on auxiliary fuels and quality of burden materials
C. Thermal attack, based on heating enrichment resulting in higher operating temperatures
2.4.1.4 Provide alarms linked to a constantly attended location if the fans associated with the bag house
fail.
2.4.1.5 Provide thermocouples throughout the blast furnace, including the following locations:
• Cooling water (to monitor heat and load)
• Under the hearth
• Within the hearth walls
• Within the stack
• Near the stockline
• Throughout the inner wall both above and below the burden
2.4.1.6 Undertake regular thermographic scans of potential weak points in the blast furnace (i.e., at tap holes,
slag holes, and tuyeres).
2.4.1.7 Provide additional refractory thickness monitoring of the hearth that allows an estimation of the
salamander size and hearth wear.
2.4.1.8 Provide the following blast furnace monitoring and controls:
• Blast pressure
• Blast temperature
• Stock line temperature
• Top pressure
• Blast volume
• Stove-stack temperature
• Stove-dome temperature
• Hot-blast temperature
• Combustion control for stove burners with dome and stack temperature control
• Sequence recorder for large-bell movement and revolving distributor operation

2.4.1.9 Provide alarms linked to a constantly attended location for the following:
• Low gas pressure
• High stove-dome temperature
• High stack temperature
• Low blast pressure

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7-25 Molten Steel Production
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2.4.1.10 Provide spare parts for critical pieces of equipment, including but not limited to the following items
for the blast furnace:
A. Ore handling equipment: skip cars, rails, hoist drums, a gearbox and motor for the hoist. For modern
blast furnace feed conveyor, spares for all moving parts, and a spare feed belt.
B. The furnace top: complete spare top, bell segments, distributor gear, and bell rods.
C. Water-cooled components: multiple cooling plates, staves, hot blast valves, stove valve, and tuyere
coolers.
D. Bustle pipe, blow stock material, and tuyeres: multiples of these components to expedite an emergency
repair. Provide additional inventory of tuyeres above the number typically needed to replace those that
are consumed in normal operation.
E. Tap hole assembly: complete set of spares for the mud gun and drill. Spare tap hole refractory and
assembly, including refractory block for the local hearth side wall.
F. The furnace hearth: hearth steel of proper thickness and curvature, and sufficient spare hearth side
wall block material for patch repair in case of breakout. Maintain a complete set of spare beams for the
bottom of the hearth for furnaces that are near end of life or have known hearth problems.
G. Flue gas and bag house: spare in-line fans and motors for the bag house.
H. Turbo blowers: at least one in-line assembled spare blower. In addition to the in-line spare blower,
provide a spare set of rotors and diaphragms and key parts. Provide spare parts for any gear box present
between the driver and blower.
An alternative to providing adequate spares is to provide a contingency plan for a breakdown event. In order
for the contingency plan to be a viable alternative, the lost production time must be less than the replacement
time of the parts. Review the contingency plan on an annual basis.

2.4.2 Arc Furnaces

2.4.2.1 Provide cooling water monitoring that includes leak detection, high and low temperature, and high
and low air flow. Link the alarms to a constantly monitored location.
2.4.2.2 Provide a viable spare arc furnace transformer of at least equal size. Ensure the spare arc furnace
transformer is stored in a safe, clean, dry location (not outside or in the path of molten material traffic).
2.4.2.3 Provide refractory thickness monitoring of all furnaces, particularly in areas where gunnite has been
applied.
2.4.2.4 Provide alarms linked to a constantly attended location if the fans within the bag house fail.
2.4.2.5 Provide spare parts for critical pieces of equipment, including but not limited to the following items
for the electric arc furnace (EAF):
A. Hearth: side panels, top panels, and roof panels. A complete hearth bottom onsite or shared between
a number of locations.
B. If a twin shell arc furnace is in use, provide a spare slew bearing for under the arc furnace mast. Store
the spare slew bearing in oil to maintain its condition.
Note: Similar exposures exist with a system called “Con-Arc,” where the arc mast swings between two
large ladles used for AOD converting.
C. Electrical supply: spare delta closure and surge packages.
D. Bag house: in-line spare motors and fans.
An alternative to providing adequate spares is to provide a contingency plan for a breakdown event. In order
for the contingency plan to be a viable alternative, the lost production time must be less than the replacement
time of the parts. Review the contingency plan on an annual basis.

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2.4.3 Basic Oxygen Furnaces

2.4.3.1 Provide cooling water monitoring that includes leak detection, high and low temperature, high and
low air flow, that alarms to a constantly monitored location.
2.4.3.2 Provide refractory thickness monitoring of all furnaces, particularly in areas where gunnite has been
applied.
2.4.3.3 Provide alarms linked to a constantly attended location if the fans with the bag house fail.
2.4.3.4 Provide spare parts for critical pieces of equipment, including but not limited to the following items
for the basic oxygen furnace (BOF):
A. Vessel: a complete BOF vessel, preferably not in service (new or rebuilt).
Alternatively, spare capacity can be built into the process with two large BOF vessels, with a documented
procedure in place to order a replacement vessel when wear and creep measurements show the
in-production vessel is approaching end of life.
B. Trunion: A complete BOF trunion (preferably not in service).
C. Tilt drive: trunion shaft, bull gear, tilt drive pinions, tilt motors, and gearboxes.
D. Off-gas systems: large fans and motors.
E. Degassing station: snorkels, dome, or spare vessel for degassing.
F. Argon-oxygen degasser station: a complete new or rebuilt vessel.
An alternative to providing adequate spares is to provide a contingency plan for a breakdown event. In order
for the contingency plan to be a viable alternative the lost production time must be less than the replacement
time of the parts. Review the contingency plan on an annual basis.
2.4.3.5 Provide the following interlocks for the oxygen lances: limit tilt switches, high pressure and low water
within the hood.
2.4.3.6 Provide cooling water monitoring for the oxygen lances and hood cooling. Examples of cooling water
monitoring are differential pressure cells, temperature differential, and flow metering.
2.4.3.7 Provide, at a minimum, the following computer controls with alarms if abnormal conditions occur linked
to a constantly attended location:
• Oxygen pressure
• Hood temperature
• Raw material hoppers/chute
• Oxygen volume
• Bag house temperature

2.4.4 Casting
2.4.4.1 Provide cooling water monitoring that includes leak detection, high and low temperature, high and
low air flow, and that alarms to a constantly monitored location.
2.4.4.2 Provide spare parts for critical pieces of equipment, including but not limited to the following items
for the continuous caster:
A. Turret bearing: new bearing, preferably stored and sealed in oil.
B. Casting molds and water-cooled rollers: the molds and rollers see heavy use and can overheat, wear
out, or otherwise be damaged over time. Keep several of each type on hand. Many of the spares can
be in various stages of rebuild, but maintain at least one mold and roller set in good working condition.
An alternative to providing adequate spares is to provide a contingency plan for a breakdown event. In order
for the contingency plan to be a viable alternative the lost production time must be less than the replacement
time of the parts. Review the contingency plan on an annual basis.

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7-25 Molten Steel Production
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2.4.4.3 Provide emergency pumps and emergency water (such as a gravity-fed water tank) in case of loss
of cooling system water to the continuous caster.
An alternative to providing the emergency equipment is to have a formal contingency plan that would provide
an alternative supply of cooling water for the continuous caster before damage occurred. Review and update
the contingency plan annually.
2.4.4.4 Provide an emergency power system for the ladles that will allow their removal from the continuous
caster in the event the ladle mechanisms fail to operate properly (e.g., the bottom gate fails to close).

2.5 Operation and Maintenance

2.5.1 Arc Furnaces

2.5.1.1 Implement a management system for all control program changes for the continuous caster that
includes a record of authorization by the process control manager. Keep a written record of all control program
changes for a minimum of 24 months.
2.5.1.2 Implement a management system to log any by-passes made to individual devices or protective
functions in the continuous caster control system. Keep a written record of each change. Include the following
information:
• When the device was by-passed
• When it was returned to service
• What was by-passed
• Why it was by-passed
• What hazard existed while it was being by-passed
Also include a space for all involved parties to sign the log when they bypass the system and when it is
returned to normal. Keep a copy of log entries for a minimum of 24 months. This will allow systemic issues
to be identified and addressed.
2.5.1.3 Operate and maintain cranes in accordance with Data Sheet 1-62/17-16, Cranes. Ensure all cranes
used for transporting and lifting molten metal vessels are rated for the task.
2.5.1.4 Ensure the primary switch of an arc furnace transformer that is carrying load current can only be
opened after the furnace electrodes are raised and the transformer primary ammeters show no current flow.
It has long been recognized that switching transients have been the major contributing cause in 70% of arc
furnace transformer failures.
2.5.1.5 Avoid switching the transformer while it is drawing load current. An alternative is to verify via transient
recorders and a switching transient study that the voltage transients produced by opening the arc furnace
transformer primary switch under load (electrodes down) will not cause damage.
2.5.1.6 Certain types of electric furnaces and operating conditions may not require raising electrodes prior
to performing a transformer tap change. In such cases, undertake a study to prove that the transients
produced will not be detrimental to the arc furnace transformer or the supply system. Retain a copy of the
study onsite for reference. Update the study after any major arrangement changes or after the installation of
new equipment.
2.5.1.7 Regularly inspect and test the in-service and spare arc furnace transformers (refer to Data Sheet
5-4, Transformers for further details). Keep written records of the inspections and test results.

2.5.2 Basic Oxygen Furnaces

2.5.2.1 Implement a management system for all control program changes for the continuous caster that
includes a record of authorization by the process control manager. Keep a written record of all control program
changes for a minimum of 24 months.

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2.5.2.2 Implement a management system to log any by-passes made to individual devices or protective
functions in the continuous caster control system. Keep a written record of each change. Include the following
information:
• When the device was by-passed
• When it was returned to service
• What was by-passed
• Why it was by-passed
• What hazard existed while it was bying by-passed
Also include a space for all involved parties to sign the log when they bypass the system and when it is
returned to normal. Keep a copy of log entries for a minimum of 24 months. This will allow systemic issues
to be identified and addressed.
2.5.2.3 Undertake annual inspections of the basic oxygen furnace trunion for cracks or water leaks.
2.5.2.4 Monitor creep and deformation in the basic oxygen furnace trunion ring at least every 6 months.
Maintain a written record of the results to track the condition of the trunion. Replace or repair the rings if there
is a large shift in the creep or deformation trend.
2.5.2.5 Monitor the flow and quality of gases (e.g., oxygen, nitrogen, argon, and hydrocarbon coolants) into
the BOF. Connect the monitors to a constantly attended location.

2.5.3 Casting
2.5.3.1 Implement a management system for all control program changes for the continuous caster that
includes a record of authorization by the process control manager. Keep a written record of all control program
changes for a minimum of 24 months.
2.5.3.2 Implement a management system to log any by-passes made to individual devices or protective
functions in the continuous caster control system. Keep a written record of each change. Include the following
information:
• When the device was by-passed
• When it was returned to service
• What was by-passed
• Why it was by-passed
• What hazard existed while it was being by-passed
Also include a space for all involved parties to sign the log when they bypass the system and when it is
returned to normal. Keep a copy of log entries for a minimum of 24 months. This will allow systemic issues
to be identified and addressed.
2.5.3.3 Conduct annual testing of the emergency cooling system for the continuous caster. Keep a written
record of the testing for future review.
2.5.3.4 Conduct annual testing of the emergency power system for the ladles. Keep a written record of the
testing for future review. Test the ladle empty, half full, and full to ensure proper functionality.

2.6 Human Factor

2.6.1 Develop a procedure for safe operation of the electrical systems for the furnaces. Include in the
procedure the direction not to reclose the primary circuit breaker before whatever caused the primary switch
to operate is corrected. Ensure the procedure is easily accessible by the furnace operators.
2.6.2 Develop and maintain an emergency plan for process upsets for all furnaces onsite. Review the plan
every 12 months and keep the line of authority for critical decisions up to date.
2.6.3 Develop a written operating philosophy for all furnaces onsite that covers relines, patching, and minor
repair/relines, and lists the last major reline and the planned next full reline. Include de-sculling procedures
for the basic oxygen furnace vessels, lances, and slag pots.

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7-25 Molten Steel Production
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2.6.4 Develop and maintain an emergency plan for process upsets or molten metal breakout on the casting
machines. Include in the plan actions to be taken in the event of the loss of electrical power, loss of cooling
water, and molten metal breakouts from the ladle, tundish, or mold. Conduct regular training involving the
castor operators.

2.7 Contingency Planning

2.7.1 At a minimum, develop contingency plans for the following situations. Include in the plan a list of
suppliers for critical and long lead time equipment for which a spare in not held onsite. Document and review
the plans on a annual basis.
A. Raw material feeds: Include in the plan an alternative method for delivering the raw materials to the
blast furnace.
B. Arc furnace transformer failure: Include in the plan a process for installing the spare arc furnace
transformer and sending the damaged one out for repair.
C. Basic oxygen furnace trunion failure: Include in the plan a process for bringing the spare trunion or
BOF vessel online and repairing or replacing the damaged trunion.

2.8 Electrical
2.8.1 Do not use oil-filled circuit breakers as the primary switch for any type of furnace.
2.8.2 Provide a trip counter on all circuit breakers and primary switches to record each time the circuit breaker
or switch operates.
2.8.3 Maintain and operate arc furnace transformers in accordance with Data Sheet 5-4, Transformers.

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 General
In the iron-making process, iron is separated from the iron ore by one of three processes: blast furnace,
direct reduction, or iron smelting.
Technology is continually improving and production control systems are more sophisticated, so blast furnace
campaign lives have been increased from 5 years to more than 10 years.
An integrated mill is a large, high-capacity facility that includes all the different processes to make steel from
ore. A typical integrated mill will have coke ovens for turning coal into coke, a blast furnace for turning ore
into molten pig-iron, a basic oxygen furnace to turn pig iron into steel (probably with some scrap added), a
ladle furnace and/or vacuum furnace for adjustment of chemistry, a caster, a re-heat furnace, and a rolling
mill. A blast furnace/basic oxygen furnace operation is difficult to start and stop. The blast furnace is a
continuous chemical process with product stored in hot molten form waiting in rail cars for the basic oxygen
furnace.
A mini-mill is a smaller, secondary steel producer using scrap steel as raw material. A typical mini-mill will
have electric arc furnaces or induction furnaces for scrap melting, a ladle furnace and/or vacuum furnace for
adjustment of chemistry, a caster, a re-heat furnace, and a rolling mill.
Because the electric arc furnace can be easily started and stopped on a regular basis, mini-mills can follow
the market demand for their products easily, operating on 24-hour schedules when demand is high and
cutting back production when sales are lower.
An induction furnace is typically used in small capacity facilities and where electrical supplies are uncertain.
The lower capital costs also make them an attractive alternative to electric arc furnaces. Refer to Data Sheet
6-3, Induction and Dielectric Heating Equipment for further information on induction furnaces.
Figure 1 shows process flows for integrated steel mills and mini mills.

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Fig. 1. Process flows for integrated steel mills and mini mills (courtesy World Steel Association)
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3.1.1 Blast Furnace (BF)

The basic steps of ore-based production in blast furnaces are:
A. The ore is crushed, homogenized, and mixed with limestone, then sintered.
B. The sintered ore is fed with coke, iron ore pellets, mill scale, flux (limestone, dolomite, etc.), and basic
oxygen furnace scale into a blast furnace.
C. Heated air (blast), coal, and gas injection burns part of the coke to produce heat for the chemical
reactions involved and to melt the iron.
Blast furnaces are costly investments; to increase productivity the volume is increased, typically to the extent
that daily production has increased from 100 tons to 1000 tons (102 metric tons to 1016 metric tons). This
increased productivity causes even more problems with the refractory lining. The thermal level within a blast
furnace is very unstable due to irregular fluxes of gas in the furnace associated with noncontinuous
combustion of coke. Since coke is very expensive, the industry has tried to use other combustibles such as
atomization of pre-heated oil, gas, or coal powder mixed with oil. However, coke is still the most common
combustible.
Blast furnaces operate continuously until they need to be relined.
The product produced from a blast furnace is liquid pig iron or solid sponge iron. Both of these products
contain large amounts of impurities. The next stage in the production of steel is the refining process, in which
these impurities are removed. This is done using a basic oxygen furnace.
Pig iron is tapped from the iron notch at the bottom of the furnace and put into torpedo cars where it is
transferred to the basic oxygen furnace.

3.1.2 Direct Reduction Iron (DRI)

While direct reduction iron processing is not strictly a molten metal process, a brief description of the process
and the hazards is provided below because the subject is not currently covered in any other FM Global data
sheet.
The direct reduction iron process is an alternative way of making iron using natural gas or coal. The process
involves the direct reduction of fine iron ore concentrates in a series of reducing gas reactors. The iron is
reduced in a solid state (in contrast to blast furnaces, which create iron in a molten state) at temperatures
ranging from 1472°F to 2012°F (800°C to 1100°C). Hot briquetted iron (HBI) is a compacted form of DRI
designed for easier handling, shipping, and storage.
In the HBI process, iron ore is reduced to approximately 93% metallic iron using a reduction gas comprised
of carbon monoxide (CO) and hydrogen (H2). The process operates at pressures as high as 160 psig (11
bar) and temperatures up to almost 1400°F (760°C).

3.1.3 Electric Arc Furnace (EAF)

Electric arc furnaces are used extensively in the steel industry for making both carbon and specialty steel,
and in the electrochemical industry for the production of ferro-alloys, phosphorus, silicon carbide, and similar
products. The arc furnace transformer is the critical component and is exposed to severe duty and subject
to extensive damage, requiring time-consuming repairs.
There are two types of electric arc furnaces in common use; the open-arc and the submerged-arc. These
are made for single-phase, three-phase, and DC operation.
The furnace itself can hold upwards of 300 tons of steel. The shell is lined with brick and refractory on the
inside and may be water cooled. The moveable hood is usually water cooled, but may also be lined. During
charging or tapping of the furnace the electrodes are raised and the hood is either rotated or tilted out of
the way. The furnace can then be tilted for tapping, or, in newer furnace designs, bottom tapping is provided
that alleviates the need for tilting.
In many cases a small (or even a moderate) amount of metal is intentionally left in the bottom (called the
heel) to preheat the next scrap load. This also allows any moisture in scrap to be driven off early.
Three types of energy may be used to melt the charge: electrical, chemical (oxygen reacting with carbon),
and heat of combustion using oxy-fuel burners. Productivity is a function of the net rate of energy input.

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Because of the large heat losses associated with the EAF process, conservation of energy is critical. One
of the prime ways to conserve energy is by reducing the heat time for a given charge. The issue of reducing
heat times has been an ongoing process; maximizing energy input when the power is on, and minimizing
the power off time. The terms “power utilization” (PU) and “time utilization” (TU) have been coined. PU is the
average power input/maximum power input when power is on. TU is the percentage of tap-to-tap time when
the power is on.
The typical EAF hearth is a shallow bowl made of steel lined with refractory. The modern EAF exhaust system
(one that can handle exhaust from 150 MW arc furnace plus many oxygen fuel burners) is an elaborate
system starting with cooling sections similar to a BOF hood and with a spark arrestor section, then leading
finally to a multi-section bag house.

3.1.3.1 Arc Furnace Transformers (AFT)

The arc furnace transformer is designed for operation with short circuit arcing on the load side for periods
of 1 hour out of every 1.5 to 2 hours. AFT designs have a shorter life span (typically 10 to 20 years) than power
transformers (typically 35 to 40 years). A spare arc furnace transformer is essential. They are available in
sizes ranging from 200 kVA to over 100 MVA. The transformer windings are normally oil-immersed and
water-cooled, although some have natural or forced oil circulation. Most modern units employ external heat
exchangers for cooling the oil.

3.1.4 Basic Oxygen Furnace (BOF)

Basic oxygen furnaces take molten iron produced in a blast furnace along with scrap steel and various raw
materials and refine them into molten steel. In the refining stage iron is processed in either a basic oxygen
furnace (BOF), or an electric arc furnace. The BOF is a pear-shaped vessel in which the molten iron is refined
by blowing oxygen into the liquid metal by water-cooled lances, and combined with various fluxes and alloys.
The basic oxygen furnace vessel is cradled in a complex water-cooled trunion with shaft and mechanisms
to provide tilting (nearly 360 degrees of motion) for skimming slag and pouring steel “heats” (industry term for
a batch of molten steel) into ladles. The tilt is usually accomplished with several planetary drive gears turning
a large bull gear that rotates the trunion shaft (Figure 2).
The molten pig iron is tapped from a blast furnace at regular intervals (usually every few minutes) and the
iron is carried to the blast oxygen shop (also known as the BOF shop or blast oxygen process [BOP] shop)
via heavy iron refractory-lined tank cars. Basic oxygen furnaces need to be kept in production to maintain
the flow of pig iron from the blast furnace; otherwise, the blast furnace would have to shut down.

3.1.5 Steel Refining Process

Following the steel-making stage, which can be done via a basic oxygen furnace or an electric arc furnace,
the liquid steel may go through a ladle refining process where the primary function is the tailoring of the heat
chemistry to produce specific grades of steel. Ladle refining refers to the metallurgical processes that are
done in the ladle, such as: alloying, degassing, reheating, and stirring. Producing the correct steel chemistry
can be done by simply adding bulk alloy, lumps or chunks of alloy, or injectable or wire-encased powders
during the ladle refining process. Most ladle refining is accomplished using electric arc furnaces, although
some locations use plasma torches.

3.1.6 Casting
The molten metal from the refining stage is poured into a ladle. From the ladle there are two methods used
for processing ingot and continuous casting.In the older method, molten metal is poured into ingot molds
if ingot casting is undertaken. After solidifying, the ingot goes to a primary rolling mill, which produces slabs
or blooms (refer to Figure 3).
The more modern process is the use of continuous strand casters. The molten metal from the ladle is poured
into an intermediate container called the tundish. The tundish is a large refractory-lined vessel that feeds
the mold using a special delivery nozzle that extends into the mold. The liquid steel flows from the tundish
into a water-cooled mold and freezes superficially. The tundish can deliver molten steel to the mold
continuously while the empty ladle is moved away and replaced by the next full ladle. The mold is a special
copper-lined device supported by an oscillating cradle (the rocking motion helps keep the distribution of
molten metal within the mold even). The metal is then drawn downward, guided by a series of spray water
cooled rollers while it continues to cool (see Figure 4).

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Automatic and remote manual valves

Product lines with block valves
Depressurization system
Dump system

Relief valve
To flare stack
burning pit, or
Condenser incinerator

Knockout tank

Column
Rupture
disc
To user
Raw materials
tanks Product tanks
Reactor

To user

To dump tank or
burning pit

Fig. 2. Basic oxygen furnace components.

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Cast ingot
Cast ingot

Heat up in soaking pit, Heat up in soaking

then rolled on pit, then rolled on
bloom (primary) slab (primary)
mill into a... mill into a...

Bloom Slab

Re-heated and
Rolled on rolled on
bar bill roughing
in to a... mill in to a...

Bar
ready for finish shapes mill
Strip
Ready for finish mill

Fig. 3. Cast steel products via ingots

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Next ladle
ready
Ladle
pouring

Bearing Tundish
Mold

Roller
segments

Fig. 4. Continuous Caster

4.0 REFERENCES

4.1 FM Global
Data Sheet 1-6, Cooling Towers
Data Sheet 1-62/17-16, Cranes
Data Sheet 5-4, Transformers
Data Sheet 5-31, Cables and Bus Bars
Data Sheet 6-3, Induction and Dielectric Heating Equipment
Data Sheet 7-11, Belt Conveyors
Data Sheet 7-21, Rolling Mills
Data Sheet 7-32, Ignitable Liquid Operations
Data Sheet 7-33, Molten Materials
Data Sheet 7-76, Prevention and Mitigation of Combustible Dust Explosions and Fires
Data Sheet 7-98, Hydraulic Fluids
Data Sheet 7-101, Fire Protection for Steam Turbines and Electric Generators
Data Sheet 7-104, Metal Treatment Processes

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APPENDIX A GLOSSARY OF TERMS

Arc furnace transformer (AFT): A specialized transformer used in the steel industry for making both carbon
and specialty steel. The transformer produces electric arcs between electrodes that provide the energy to
melt the steel.
Argon oxygen decarbonization AOD: This process is used almost exclusively to produce stainless steel and
other high-grade alloys. The AOD lowers the carbon levels within the molten metal batch by regular injections
or oxygen mixed with argon. The mixing of argon with the oxygen reduces the chances of oxidizing the alloys.
Basic oxygen furnace (BOF): This process is used to transform iron into steel and is the most efficient way
of producing low and medium carbon and alloy steels. Oxygen is blown onto the surface of the molten iron
to help assist in the process.
Blast furnace (BF): A blast furnace is used to make iron from raw materials such as iron ore, lime, and coke.
Breakout: The uncontrolled release of molten material from the inside of a furnace, ladle, mold, or other
vessel.
Degassing: This process is used to remove unwanted excess gas from the molten steel mix, which increases
the quality of the steel.
Directly reduced iron (DRI): Also known as “sponge iron,” it is produced by reducing the raw iron ore into
pellets and is an alternative way of making iron (as opposed to using a blast furnace).
Electric arc furnace (EAF): A furnace used to create steel from scrap. The steel is melted using electric arcs
from electrodes that are placed next to or submerged in the melting scrap.
FM Approved: The term “FM Approved” is used to describe a product or service that has satisfied the criteria
for Approval by FM Approvals. Refer to the Approval Guide for a complete list of products and services that
are FM Approved.
Hot briquette iron (HBI): Hot briquette iron is a compact form of directly reduced iron. HBI is produced to
improve the ease of handling, storing, and shipping iron products.
Integrated mill: An integrated mill has both iron- and steel-making processes on the same site, as well as
downstream casting, rolling, and finishing. The integrated mill will have at least one blast furnace onsite.
Ladle metallurgical furnace (LMF): This furnace is used to adjust the metallurgical properties of the molten
steel prior to the casting process.
Ladle refining station (LRS): Similar to the ladle metallurgical furnace.
Mini mill: A facility that makes steel from scrap steel rather than iron. A mini mill will have either an electric
arc furnace or induction furnace to melt the steel scrap, as well as a casting process. The mill may also have
downstream processes such as rolling and metal treatment processes.
Slag: The waste byproduct produced during iron and steel making. The slag is lighter than the iron or steel
and floats on top. It is drawn off at regular intervals to help maintain the optimal environment within the
furnace.
Trunion: The cradle that the basic oxygen furnace vessel sits in. The trunion also houses the water cooling
system for the furnace and provides the means to tilt the vessel to skim off the slag and pour the steel into
the waiting ladles.
Tundish: The container used for pouring molten metal into a mold during the casting process.
Tuyeres: The nozzles used to deliver oxygen and combustion air into the interior of the blast furnace.

APPENDIX B DOCUMENT REVISION HISTORY

October 2013. Removed recommendation 2.4.1.2 on top gas monitoring on blast furnaces as it was technically
invalid.
January 2013. This is the first publication of this document.

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APPENDIX C BIBLIOGRAPHY
Cramb, A. W., ed. The Making, Shaping and Treating of Steel: Casting Volume. 11th Edition. AISE Steel
Foundation, 2010.
Degner, M., et al. Steel Manual. Steel Institute VDEh, 2008.
Fruehan, R. J., ed. The Making, Shaping and Treating of Steel: Steel Making and Refining Volume. 11th
Edition. AISE Steel Foundation, 1998.
Greerdes, M., H. Toxopeus, and C. van der Vliet. Modern Blast Furnace Ironmaking: An Introduction. 2nd
Edition. Ios Press BV, 2009.
Wakelin, D. H., ed. The Making, Shaping and Treating of Steel: Iron Making Volume. 11th Edition. AISE Steel
Foundation, 1999.

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