Here’s a look at how steel is produced in a steel mill or factory, and what the “smartization” of steel factories will look like.

So, how is steel made?

Iron Making

To make steel, manufacturers first need molten iron. Molten iron comes from two raw materials; iron ore and coal. Iron ore is converted into sinter ore in a sintering plant and coal is converted into raw coke using a coke oven. The processed materials are poured into a blast furnace where hot air reaching 1200℃ is blown in from the bottom through tuyeres, causing a chemical reaction. This process oxidizes the coke and reduces the sintered ore, creating molten iron.   

Steelmaking

In the steelmaking stage, the molten iron is transported to the steel making plant via a torpedo car, where the liquid is poured into a converter. Then, oxygen is blown into the converter to burn off all the impurities. All that is left is pure molten steel.

Continuous Casting

This is where steel finally becomes solidified into different shapes such as slab, bloom and billet. Liquid steel is poured into molds and cooled as it passes through a continuous casting machine until it solidifies into the desired shape.

Hot steel passes through rolling machines to be rolled into specific sizes and thicknesses. (Source: Global Sourcing Blog)

Rolling Process

During the rolling process, steel is heated once more to achieve various sizes and thicknesses. Steel slabs are heated to over 1100℃, then pass through rolling machines. This results in hot-rolled coils that can be shaped for different uses such as thick plates. They can also be processed into long, wire-shaped rods for billets. Often, the hot-rolled coils are rolled at room temperature for cold-rolled coils. Cold-rolled coils can be fabricated to produce galvanized and electrical steel products.

“Smartizating” these processes will involve converging IoT, Big Data, and AI to connect the different facilities, IT systems and workers in order to collect and analyze data for optimization.

POSCO is “smartizing” the steel-production process

POSCO is a steel company looking to lead the industry in adopting smart factories. CEO Kwon Ohjoon made “smartization” one of the 4 key priorities for POSCO starting back in 2014, and Kwon will continue to increase those investments.

POSCO smart factory incorporates artificial intelligence to enhance safety and efficiency.

SEE ALSO: How Smart Factories are Changing the Manufacturing Industry

In 2016, POSCO established its Smart Solution Council in order to research AI, big data and IoT applications. In the same year, POSCO ICT’s smart factory platform, PosFrame, was completed and installed in POSCO’s Gwangyang Steel Mill. PosFrame allows engineers to collect and monitor big data. So far, the company has saved over USD 14 million by incorporating the new technology in its production practices.

Here are some other features of POSCO’s Smart Factory.

POSCO’s Smart Blast Furnace

The Pohang Blast Furnace No.3 became a smart furnace in 2017, following a 102-day repair period. The furnace is now equipped with automated sensors that monitor and control its internal conditions using AI technology. Smart sensors monitor the blast furnace for factors like raw material quality and ventilator status, preventing breakdowns and ensuring a much longer lifecycle.

SEE ALSO: Will Artificial Intelligence Lead to Breakthroughs in the Steel Industry?

Worker Safety

Smart sensors can be used for more than just process monitoring. The company is working toward a full implementation of smart sensors for safety purposes, using IoT to create a better working environment.

Steel manufacturing involves high temperatures and high pressure levels, which is dangerous for workers who come in close contact with the equipment. With smart sensors monitoring all of the factory information, workers will instead be monitoring operation from a safe distance.

Workers in POSCO’s smart factory wear smart sensors for safety.

Wearable sensors, in conjunction with factory smart sensors, will be able to detect if and when workers are approaching potentially dangerous areas, and will alert them. These sensors will also detect and alert with regards to any impending accidents, or life-threatening situations like gas leaks, explosions, or fires.

Also, dust, sulfur, and nitrogen compounds will be removed via a high-plasma method, creating an eco-friendly steel plant and a healthier environment for workers.

POSCO will continue to add more smart features to its steel mills to increase efficiency, safety and sustainability. In efforts to learn and implement new technologies, POSCO CEO Kwon Ohjoon visited GE’s smart factories to learn about their technology earlier this year. POSCO also held the 2017 Smart POSCO Forum to share its insights with clients and affiliates, all as part of its expanding smartization efforts.

It’s a common theme, and the images that pop into mind may be of early humans during the Iron Age.

But according to Professor Seohyung Kim of Inha University, the history of iron precedes the history of life, and so historians need to look back to the beginning of the universe to fully understand the way iron has shaped humankind and its environment. She gave a special lecture called “History of Iron: Universe, Life and Human,” as part of the exhibition on October 13. Professor Kim studies history from a Big History perspective, or a multi-disciplinary approach to the study of the past that combines science, geology, human history and more to get a better, bigger picture of the past, present and future.

So here’s a look back, way back, into history to see what iron has to do with the history of man.

Stars Exploded and then Iron Existed

Where did iron come from? The stars. To be exact, large, dying stars. In the beginning of the universe, there were only 2 elements in existence- helium and hydrogen. New elements are only created when protons and neutrons fuse together and this requires a lot of heat.

The temperature of a star rises when it uses up all of its hydrogen atoms, and when it uses up all of its helium atoms, it collapses, emitting even more heat. This cycle repeats itself, creating new elements in the process until finally, iron in created. Elements with greater mass than iron are created in a supernova, or the death of a really, really big star.

A piece of meteoric iron formed by the heating and collapsing of a star sits on display at the National Museum of Korea.

So, why is this important?

The variety of elements created by exploding stars are what planets are made of, including earth, and iron makes up 35 percent of the earth’s entire mass.

Humans and their Complex Brains

After the formation of the earth, simple life forms appeared, and then eventually primates and homo sapiens. Humans are the most powerful species on earth, largely due to their complex brains that allowed for the development of language and through it, collective learning.

Iron-rich red meat was an important factor in human-brain development. (Source: Omicrono)

What’s interesting is that around 2.5 million years ago, humans started eating meat rich in iron and calories. Before this change in diet, early humans spent most of their scarce energy on chewing and digesting large amounts of vegetation. With the introduction of meat, their brains got larger as it is a muscle that requires 20 times more energy than muscles in other parts of the body. When humans started cooking meat with fire around 500,000 years ago, they consumed even greater amounts of meat, meaning humans could meet their dietary iron needs, and put their larger brains to use for things like agriculture.

Agriculture and Civilization

Collective learning led to some of the most critical developments is history, including agriculture, which developed after the end of the last ice age about 11,700 years ago, as human populations increased due to the fact that they were able to cook and consume meat. Further advancements in farming tools during the Iron Age led to an abundance of food and massive civilizations.

Some iron tools that made farming easier are on display at the National Museum of Korea.

Weapons Made Stronger with Iron

However, farming tools were not the only places where iron was applied. As communities developed around abundant agricultural centers, people decided they wanted more land, labor and power. So, cities waged war on one another with iron tools and armor that were fatally strong.

The Iron Age brought forth improvements in soldiers’ armor, and can be seen at the National Museum of Korea.

One vital invention in the evolution of weapons and tools alike was the wheel. The oldest artifact of the wheel is a potter’s wheel found in Mesopotamia and dates back to about 3500 BC. Then came the wooden wheel that were attached to chariots for effective warfare. Then finally, the Celtics applied iron rims on their chariots for added strength, durability and speed. Paired with iron swords and armor, wars became vastly efficient.

Iron wheels, like this one on display at the National Museum of Korea, enhanced existing wooden wheels.

After many years, the Chinese invented gunpowder triggering a new era of warfare. Iron was used to make rifles, cannons and other gunpowder machines to wipe out massive amounts of people at a time.

The invention of gunpowder led to new weapons such as these Iron rifles on display at the National Museum of Korea.

From Iron to Steel

After centuries of iron spearheading the development of new technologies and civilizations alike, a man named Henry Bessemer introduced a process to produce pure iron with a converter in 1856, known as the Bessemer Process. This invention would lead the way to the commercialization of steel and then eventually the industrial revolution near the end of the 18th century.

The steel industry was met with a rampant rise in steel demand during the second industrial revolution nearly a century later, with the introduction of electricity, gas and oil. Steel consumption continued to thrive into the third industrial revolution as it served the foundations for electronics, computers and automated production systems. As the world enters the fourth industrial revolution, steel will continue to be the bedrock of leading innovation and technology including electric vehicles, sustainable energy facilities and smart manufacturing factories.

Automated robots are part of what workplaces will look like in the fourth industrial revolution. (Source: Business Insider)

Looking back on history, the role and value of iron and steel in human development is indisputable. And to think, it all started with the death of a star.

Cover photo courtesy of BBC.