Everyone is aware of stainless steel’s journey from sheets to utensils, tables, bridges, vehicles, etc. but how is stainless steel made? Yes, it is made of iron, but what lies at the core of the process? Have you wondered how this strong, versatile metal is created from iron ore? The iron-to-steel process is quite fascinating, and this blog will walk you through it. This blog discusses the origin of steel in detail, the difference between iron and steel, the steps in iron processing, and how raw ore results in this aesthetic metal.
Read on!
Iron ore is a naturally occurring mineral on Earth. In its raw form, it is unrecognisable, but once extracted and refined, it becomes a crucial material that is used for many purposes. It is one of the most abundantly found metals in the Earth’s crust.
Some iron ore types are:
Hematite: It is one of the most common types, which is widely used across industries.
Magnetite: As the name suggests, it has high magnetic properties, and it is also a widely used ore.
Limonite: It is a lower grade of iron ore but is used in some specific applications.
Siderite: This ore is very difficult to process and thus remains uncommon.
These are the purest forms of iron ore.
Iron is a chemical element that is made from iron ore. When the ore is extracted, refined, and processed, it creates iron. It is relatively soft and prone to rust.
On the other hand, steel is an alloy. It mostly contains iron, but chromium, carbon, nickel, and other elements are added to make it aesthetic, strong, durable, and corrosion resistant.
We can say that steel is a more refined and processed form of iron.
Here is the process of how iron is made from iron ore:
Mining: Though iron ore is abundantly available, its mining is difficult. It is found in mines or open pits across the world.
Crushing and Grinding: The ore is then broken down into smaller pieces to process further.
Concentration: During the process, hematite and magnetite are separated from other minerals, thus increasing the concentration of iron in the mix.
Smelting: Limestone and coke are used to remove the impurities. The chemical reaction causes slag to come up, and it is removed, leaving pure iron in its wake.
At the end of this process, we get iron. It is then further processed to make steel.
Pelletizing is the process of breaking down iron ore into finer particles for even processing.
This process takes place before the iron ore is poured into the blast furnace.
It has three stages:
Preparation: Iron ore is ground into a fine powder. Then, the binders are added, such as bentonite, dolomite, or limestone. It improves the ore’s quality and strength.
Balling/ Pelletizing: The ground mixture is poured into a pelletizer, and water is added. The mixture is rolled into green pellets.
Induration/ Hardening: Heating and cooling treatments are used to dry the pellets and pour them into the blast furnace.
This process reduces energy waste and enhances the performance of blast furnaces in steel production.
There are two processes of turning iron into steel:
The molten iron is poured into the furnace, and oxygen is added to the mix. It causes impurities, such as carbon, manganese, phosphorus, etc., to oxidize. Limestone is added to remove impurities that gather on top of the molten metal.
This is the modern method of steel making, which uses an electric arc to generate the heat. The method is more popular for melting and refining used or scrap steel. As the hot metal is poured into the furnace, scrap steel is added to the mix.
This method is considered more flexible and sustainable than the blast oxygen furnace.
The following are the varied uses of iron and steel in modern industries:
Iron Uses
Steel Uses
Steel is used across various industries, including but not limited to:
Steel production is an energy-intensive process and causes abundant carbon emissions. However, times are changing. Recycling is very popular today, as more and more businesses are focused on sustainability and are relying on recycled steel too. Carbon capture technologies are also contributing to protecting the environment. Also, the use of hydrogen in steelmaking is another feat that is reducing the environmental impacts of steel production.
As for the economic benefits, the steel industry supports thousands of jobs and is crucial for infrastructure, transportation, and national defense. With evolving technologies, the sector is becoming more sustainable and cost-effective.
The journey from iron ore to steel is complicated but fascinating. These materials shape your world, and thus, you must always source steel that has been manufactured responsibly. Enquire about the source and support responsible manufacturing by choosing the right supplier.
If you are looking for high-quality steel, visit New Mexico Metals LLC. We source only the best quality metals, including steel, stainless steel, bronze, copper, brass, etc. We stock various grades and line items for you to choose from.
Visit us for top-quality steel in Phoenix and Mesa.
Que: What are the main types of iron ore used in steelmaking?
Ans: The main types of iron ore are Hematite, Magnetite, Limonite, and Siderite.
Que: What is the difference between iron and steel?
Ans: Iron is a pure chemical element extracted from iron ore, while steel is an alloy. It has other elements such as chromium, nickel, carbon, etc., which enhance its durability, strength, and corrosion resistance.
Que: How is iron extracted from iron ore?
Ans: Iron is extracted through the smelting process. Limestone and coke are mixed into the molten iron ore mixture, which creates the slag and removes all impurities, leaving only pure iron behind.
Que: What is iron ore pelletizing?
Ans: It is the process of grinding iron ore into small, even balls to improve furnace efficiency and reduce energy usage.
Que: What are the main methods of steel production?
Ans: The two main methods of steel production are Basic Oxygen Furnace and Electric Arc Furnace. BOF involves blasting oxygen into the molten iron ore mixture to reduce carbon content. EAF involves adding scrap steel into the mix and melting it with an electric arc.
To meet the needs of both wholesale and retail customers by providing an extensive selection of metals cut to size with exceptional service.
New Mexico Metals LLC
Address: 5821 Midway Park Blvd NE # F, Albuquerque, NM 87109, United States
Phone: (505) 717-1900
FAX: (505) 717-1769
Email: info@newmexico-metals.com
8:00 AM - 5:00 PM Monday - Friday
9:00 AM - 12:00 PM Saturdays
Copyright © 2025. All Rights Reserved.
Website Design & Digital Marketing By WSI
