The Traditional Steel Production Process and Its Challenges
1. The Conventional Steelmaking Process
The traditional steel production process primarily relies on blast furnaces and basic oxygen furnaces (BOF). These methods involve the reduction of iron ore using coke, which is derived from coal. The process follows these key steps:
- Coke Production – Coal is converted into coke in ovens, a process that releases large amounts of carbon dioxide.
- Iron Ore Smelting – The coke is combined with iron ore and limestone in a blast furnace to produce molten iron.
- Steel Refining – The molten iron is transferred to a basic oxygen furnace, where oxygen is blown through the molten metal to remove impurities and convert it into steel.
This process is energy-intensive, emitting vast amounts of CO₂ and other greenhouse gases. Steel production is estimated to contribute 7-9% of global carbon emissions, making it one of the most environmentally damaging industrial processes.
2. The Push for Greener Alternatives
With the growing urgency to combat climate change, industries worldwide have been looking for alternative methods to reduce emissions from steel production. Some of the approaches under development include:
- Hydrogen-Based Steelmaking (H2DRI) – Using hydrogen instead of coke to reduce iron ore, cutting carbon emissions significantly.
- Electric Arc Furnaces (EAF) – Recycling scrap metal using electricity instead of coal.
- Carbon Capture and Storage (CCS) – Capturing and storing CO₂ emissions from steel plants to prevent them from entering the atmosphere.
However, while these methods reduce emissions, none have been able to match the efficiency and speed promised by China’s newly developed method.
China’s Revolutionary Coal-Free Steelmaking Process
1. How the New Method Works
Chinese researchers have developed an innovative process that eliminates coal use while dramatically increasing production speed. The key innovation involves ultra-fine iron ore powder and a specialized high-speed vortex lance that injects the powder into a superheated furnace. This results in instantaneous chemical reactions, producing molten iron in just a few seconds.
Key Steps of the Process:
- Ultra-fine iron ore powder is injected into an extremely hot furnace through a high-speed vortex lance.
- The rapid chemical reaction generates molten iron droplets almost instantly.
- The molten iron collects at the bottom of the furnace, forming a continuous stream of high-purity liquid iron.
2. Unprecedented Speed: 3,600 Times Faster
With this method, steel production takes only 3 to 6 seconds, compared to 5 to 6 hours using conventional blast furnaces. This is a 3,600x improvement in efficiency, reducing production time to a fraction of what was previously required.
3. Compatibility with Low-Grade Iron Ore
Another major advantage of this process is its ability to utilize low-grade iron ore, which is more abundant and cheaper than high-quality ore. Traditional methods require high-purity iron ore, making production costly and heavily dependent on imports. With this new method, China can use its domestic iron ore resources more efficiently, reducing reliance on imported materials.
Comparing Traditional vs. New Steelmaking Methods
The following table highlights the key differences between conventional blast furnace steelmaking and China’s new coal-free method:
| Aspect | Traditional Steelmaking | New Chinese Method |
|---|---|---|
| Production Time | 5 – 6 hours | 3 – 6 seconds |
| Coal Usage | High | None |
| Energy Consumption | 100% (baseline) | ~67% (33% less energy) |
| Carbon Emissions | High | Significantly reduced |
| Ore Type Required | High-grade iron ore | Low-grade iron ore |
| Environmental Impact | High | Low |
This comparison underscores the significant advantages of China’s new process, both in terms of efficiency and sustainability.
Economic and Environmental Impact
1. Lower Energy Costs and Production Expenses
By eliminating coal usage and reducing energy consumption by one-third, the new method is expected to cut production costs significantly. Steel manufacturers could benefit from higher profit margins while maintaining high output.
2. Reduced Carbon Footprint
Steel production is one of the largest sources of industrial CO₂ emissions. By switching to a coal-free method, China could:
- Lower national carbon emissions, supporting its goal of carbon neutrality by 2060.
- Reduce global greenhouse gas emissions, helping combat climate change.
- Improve air quality by cutting coal-related pollution, benefiting public health.
3. Strengthened Domestic Steel Industry
China is the world’s largest steel producer, accounting for over 50% of global output. By implementing this breakthrough method, the country could:
- Enhance global competitiveness, as faster, greener steel production makes Chinese steel even more attractive in international markets.
- Reduce reliance on imported iron ore, securing greater self-sufficiency in raw materials.
- Expand its influence in global steel trade, potentially reshaping market dynamics.
Baosteel Desheng Completes Installation of Advanced VOD System to Enhance Specialty Steel Production
The installation of the VOD system is a crucial step in Baosteel Desheng’s long-term strategy to enhance its stainless steel manufacturing processes. The VOD unit, with a capacity of 120 tons per heat, significantly improves the removal of carbon and other impurities from molten steel, resulting in purer and higher-quality stainless steel.
How the VOD System Works
The Vacuum Oxygen Decarburization process plays a key role in refining stainless steel by using a combination of vacuum and oxygen to remove carbon without significantly affecting chromium levels. This process ensures:
- Enhanced Carbon Removal – The VOD system effectively eliminates carbon from the molten steel, allowing for the production of ultra-low carbon stainless steel, which is essential for high-performance applications.
- Reduced Impurity Levels – Besides carbon, the system removes other unwanted elements such as sulfur, nitrogen, and hydrogen, ensuring a high-purity final product.
- Energy Efficiency – The advanced metallurgical process requires lower energy consumption than conventional methods, leading to cost savings in the long run.
- Greater Alloy Flexibility – The system allows Baosteel Desheng to work with a broader range of alloy compositions, improving product versatility and customization for different industrial applications.
The Importance of VOD in the Steel Industry
The VOD system is one of the most important secondary refining processes in the production of specialty stainless steel. Unlike conventional methods, this system operates under a vacuum, which enhances the chemical reaction kinetics, making the refining process more efficient and improving steel quality.
With the global demand for high-purity stainless steel on the rise, particularly in industries such as medical equipment, aerospace, and chemical processing, the adoption of advanced metallurgical technologies like VOD is crucial for maintaining competitiveness in the market.
Collaboration Between Baosteel Desheng and SMS Group
The successful completion of the VOD installation was the result of close collaboration between Baosteel Desheng, Baosteel Engineering and Technology Group Co., Ltd., and SMS Group. The EPC project (Engineering, Procurement, and Construction) was initiated under a contract signed in June 2020 and involved several key phases, including:
- Project Planning and Design – Engineers and metallurgical experts from SMS Group and Baosteel Engineering worked together to develop a system tailored to Baosteel Desheng’s production requirements.
- Manufacturing and Equipment Procurement – SMS Group supplied high-precision components for the VOD system, ensuring compliance with industry standards.
- Installation and Infrastructure Integration – Seamless integration of the new system into the existing plant infrastructure, minimizing downtime and production disruptions.
- Commissioning and Performance Optimization – Rigorous testing and evaluation processes were conducted to ensure the system met all performance criteria before the final handover.
The Final Acceptance Certificate (FAC) was granted by Baosteel Desheng upon successful completion of all contractual obligations, demonstrating the system’s operational efficiency, reliability, and quality performance.
Statements from Key Project Leaders
Li Jiancheng, Project Manager of Baosteel Engineering and Technology Group Co., Ltd., stated:
“SMS Group’s commitment to excellence was evident throughout this project. Their ability to deliver on all milestones ensured the successful implementation of the VOD system. This technology meets all performance expectations and will significantly contribute to Baosteel Desheng’s production capabilities.”
Matthias Oesterwind, Senior Project Manager Metallurgy from SMS Group, highlighted:
“This project underscores SMS Group’s ability to provide innovative metallurgical solutions tailored to the evolving needs of the global steel industry. We are proud to have played a role in advancing Baosteel Desheng’s production processes and look forward to continued collaboration in the future.”
Impact on Specialty Steel Production and Market Competitiveness
The completion of the VOD project marks a significant advancement in Baosteel Desheng’s ability to manufacture high-grade stainless steel. This upgrade is expected to bring several key benefits:
1. Meeting Market Demand for High-Performance Stainless Steel
Industries such as automotive, aerospace, and construction require steel products with precise chemical compositions and superior mechanical properties. The VOD system enables Baosteel Desheng to meet these stringent industry requirements, strengthening its position in the global market.
2. Cost Savings and Production Efficiency
The VOD process streamlines stainless steel refining, reducing the need for costly reprocessing steps. With a more efficient decarburization process, Baosteel Desheng can achieve:
- Lower energy consumption
- Reduced material waste
- Improved yield and production consistency
3. Environmental Sustainability and Reduced Emissions
Sustainability is a growing concern in the steel industry, and the implementation of VOD technology aligns with China’s national goals for reducing industrial emissions. The system:
- Minimizes greenhouse gas emissions by improving energy efficiency
- Reduces reliance on carbon-intensive refining methods
- Supports eco-friendly production strategies for stainless steel manufacturing
4. Strengthening China’s Leadership in Specialty Steel Production
As part of China Baowu Steel Group, Baosteel Desheng plays a critical role in advancing China’s metallurgical capabilities. The successful deployment of the VOD system reinforces China’s standing as a global leader in specialty steel production.
Potential Challenges and Future Adoption
Despite its advantages, widespread adoption of this new steelmaking process faces several challenges:
- Industrial-Scale Implementation – Transitioning existing steel plants to this method requires investment in new furnace designs and technology.
- Infrastructure Adaptation – The process may require modifications to existing supply chains and logistical frameworks.
- Workforce Training – Engineers, technicians, and workers will need specialized training to operate and maintain new equipment.
- International Adoption – Other countries may hesitate to adopt a technology pioneered in China without independent testing and verification.
However, if these hurdles are overcome, this breakthrough could pave the way for a global shift toward faster, cleaner, and more efficient steel production
A New Era for Global Steel Manufacturing?
China’s revolutionary steelmaking technology represents a monumental leap forward in industrial manufacturing. The ability to produce molten iron 3,600 times faster and without coal has far-reaching implications for economic competitiveness, environmental sustainability, and technological progress.
If widely adopted, this breakthrough could:
- Dramatically reduce global steelmaking emissions, accelerating the transition to greener industries.
- Lower production costs, benefiting manufacturers, infrastructure developers, and consumers.
- Shift international trade dynamics, as China strengthens its position as the leading steel producer.
- Inspire further innovations, encouraging other nations to develop their own cleaner and more efficient manufacturing processes.
As the world moves toward a more sustainable industrial future, China’s coal-free, ultra-fast steel production might just be the game-changer the industry has been waiting for.
Conclusion: A Major Step Forward for Baosteel Desheng and the Global Steel Industry
The successful installation of the VOD system at Baosteel Desheng’s Fuzhou plant marks a new era in stainless steel production. With a total capacity of 417,000 metric tons per year, this advanced metallurgical technology enhances production efficiency, improves product quality, and reduces environmental impact.
Through its collaboration with SMS Group and Baosteel Engineering, Baosteel Desheng has demonstrated its commitment to technological innovation, sustainability, and industry leadership. As global demand for high-purity stainless steel continues to grow, the adoption of VOD technology positions Baosteel Desheng at the forefront of next-generation steel manufacturing.
With this milestone achievement, Baosteel Desheng is well-equipped to meet the evolving needs of various high-performance industries while driving progress in China’s steel sector. The success of this project sets a benchmark for future metallurgical advancements, paving the way for more efficient and sustainable steel production worldwide.
At Lux Metal, we remain committed to providing high-quality stainless steel and precision metal solutions. As advancements in steel technology continue, we ensure that our clients receive the most cutting-edge and sustainable materials for their projects.