Name: from iron ore to shaped steel
Uploaded: 2024-09-12T16:16:25.000Z
Duration: 1 min 26 s
Channel: JoVE

La fabrication de l’acier commence par la fusion du minerai de fer en fonte dans le haut fourneau. La fusion consiste à superposer le minerai de fer avec un combustible appelé coke et du calcaire concassé dans le four.
Tout d’abord, le coke est enflammé avec un jet d’air, produisant du monoxyde de carbone, ce qui réduit le minerai en fer fondu.
Le calcaire forme un laitier, capturant les impuretés, et flotte au-dessus du métal en fusion. Ce fer fondu est ensuite égoutté pour le traitement de l’acier.
Le fer fondu contient un excès de carbone et d’impuretés. Un processus d’oxygène de base est adopté pour les éliminer. Il s’agit d’une lance à oxygène trempée dans du fer fondu et de la ferraille, à l’aide d’un flux de chaux et de spath fluor, qui forme des scories jetables en réagissant avec le phosphore.
Enfin, de nouveaux éléments métalliques peuvent être introduits pour modifier la composition de l'acier au besoin.
Lorsque l'acier atteint l'étape de coulée du four, il est soit moulé en lingots, soit traité par une machine de coulée de torons. Les lingotières peuvent avoir des diamètres de plusieurs pieds et des hauteurs allant de six à huit pieds.
De plus, l’acier fini est coulé en continu dans des formes épaisses et rugueuses appelées ébauches de poutre ou blooms.

fabrication de l'acier

Steel Manufacturing

La fabrication de l'acier est un processus en plusieurs étapes qui commence par la fusion du minerai de fer en fonte dans un haut fourneau. Cette étape initiale consiste à superposer du minerai de fer avec du coke, un type de combustible, et du calcaire broyé dans le four. Le coke est enflammé avec un volume d'air important, ce qui entraîne la création de monoxyde de carbone, qui agit pour réduire le minerai de fer en fer pur.

Au cours de ce processus de fusion, le calcaire joue un rôle crucial en formant des scories. Les scories capturent les impuretés présentes dans le fer en fusion, telles que la silice, le phosphore et l'alumine, et flottent au-dessus du métal en fusion, ce qui permet une séparation facile. Le fer en fusion purifié est ensuite drainé et déplacé vers l'étape suivante pour le traitement de l'acier.

Cependant, ce fer en fusion contient généralement un excès de carbone et d'autres impuretés qui doivent être éliminées pour créer un acier de qualité. Cela se fait par le biais du procédé à l'oxygène de base, dans lequel une lance refroidie à l'eau est plongée dans un mélange de fer en fusion et de ferraille. L'ajout de chaux et de flux de fluorine permet de former des scories en réagissant avec le phosphore, qui sont ensuite éliminées.

Après le raffinage, la composition de l'acier peut être encore modifiée en introduisant de nouveaux éléments métalliques pour répondre à des exigences spécifiques. L'acier est alors prêt à être façonné ; il est soit coulé dans des moules pour former des lingots, soit traité dans une machine de coulée en continu. Les moules à lingots sont de grande taille, avec des diamètres et des hauteurs pouvant atteindre plusieurs mètres.

L'étape finale de la fabrication de l'acier consiste à couler en continu l'acier raffiné dans des formes épaisses et brutes appelées ébauches de poutres ou blooms, qui sont ensuite prêtes à être transformées en divers produits en acier.

Fabrication de l'acier

La fabrication de l’acier commence par la fusion du minerai de fer en fonte dans le haut fourneau. La fusion consiste à superposer le minerai de fer avec un combustible appelé coke et ...

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Civil Engineering

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Masonry Materials

Matériaux de maçonnerie

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from iron ore to shaped steel

Steel manufacturing turns iron ore into steel through several controlled stages. It starts in a blast furnace, where iron ore is layered with coke and crushed limestone. The coke is a fuel, and the limestone helps remove unwanted material from the molten metal.

Air is blasted into the furnace, and the coke ignites. This produces carbon monoxide, which reduces the iron ore to pure iron. As the iron melts, limestone forms slag. Slag traps impurities such as silica, phosphorus, and alumina. The slag floats on top of the molten iron, so it can be separated easily.

The purified molten iron is drained and sent to the next stage. It still contains too much carbon and other impurities for high-quality steel. These are removed in the basic oxygen process. In this step, a water-cooled lance is lowered into a mix of molten iron and scrap metal. Lime and fluorspar flux are added to help form slag and react with phosphorus. The slag is then discarded.

After refining, the steel can be adjusted for different needs by adding new metallic elements. The finished steel is then shaped for further use. It may be poured into large ingot molds or sent through a strand-casting machine. The final products from continuous casting are thick, rough forms called beam blanks or blooms, which are ready for more processing into steel products.

From Iron Ore to Shaped Steel

masonry

Masonry Materials and Structural Uses

Masonry uses stone and man-made units such as bricks, clay tiles, terra cotta, and concrete blocks to build structures. These units can form walls, floors, and arches. Masonry is valued for strength, durability, and a wide range of visual finishes. The units are laid in rows called coursing. Mortar, a mix of water, cement, and sand, binds the units together. Building with masonry is hands-on and can be done with basic tools. A trowel applies mortar, a hammer helps adjust placement, and levels...

mortar

Mortar in Masonry: Strength and Finish

Mortar is a key construction material used to bind masonry units together. It is made from Portland cement, hydrated lime, sand, and water. In walls, it fills gaps between units and helps spread weight more evenly across the structure. That reduces weak spots and supports a stronger build. Mortar also protects masonry from outside conditions. It acts as a barrier against water and wind, which helps safeguard the inside of the structure. It can also help correct surface irregularities in...

mortar properties

How Mortar Performance Is Measured

Mortar performance is measured by several key properties that matter in masonry work. These include workability, water retention, bond strength, durability, compressive strength, volume change, and appearance. Together, these properties help determine how well mortar can be placed, bonded, and finished. Workability is the ability of mortar to be applied and moved easily. Good workability means the mortar spreads smoothly and does not sag or fall off the surface. This helps masonry units stay...

bricks

How Bricks Are Made and Fired

Bricks are made from fired clay and come in many shapes, sizes, and colors. They are a basic building material used in construction. The brickmaking process begins with local clay or shale, which is crushed, ground, and screened to make a fine material. Next, the refined clay is mixed with water to form a workable mass. That mixture can be shaped in three main ways: soft mud, dry press, or stiff mud. Soft mud bricks are made in molds with high moisture content. They may be water-struck or...

brick sizes

Brick Sizes and Modular Masonry

Brick sizes are important in construction because they affect both the look of a building and its structural strength. Bricks are measured by three dimensions: width, thickness, and length. Builders often design them to fit modular measurements, usually in multiples of 4 inches or 8 inches in width, so they work well with other building materials. Most bricks are modular bricks. These bricks are sized to include the mortar joint, which is the layer of mortar that bonds masonry units together.

brick classifications

Types of Bricks in Construction

Bricks used in construction are grouped by where they are used and by their structure. The main types include facing bricks, building bricks, hollow bricks, paving bricks, and firebricks. These categories show how one material can serve different jobs in a structure. Facing bricks, also called face bricks, are used where both strength and appearance matter. They form the visible surface of a wall, so their look is important. Building bricks are usually placed in hidden parts of a structure,...

brick durability, strength, and appearance

How Brick Quality Affects Masonry Performance

Brick quality affects how masonry holds up, looks, and performs over time. Durability, strength, and appearance are all used to judge which bricks fit a specific job. These features help builders choose bricks for walls, facades, and other construction uses. Durability is closely tied to freeze-thaw action. In freeze-thaw, water absorbed by a brick expands when it freezes. That expansion can damage the brick, especially if the water melts and refreezes. Bricks are graded for durability as SW,...

brick masonry

Brick Wall Bonds and Wythes

Brick masonry is built from individual bricks set in mortar to form walls. A key unit in this system is the wythe, which is a vertical layer of bricks one brick thick. Inside a wythe, bricks can be arranged in different courses, or rows, to build the wall. The most common course is the stretcher course. In this pattern, each brick lies with its long edge horizontal and its face parallel to the wall. Thicker walls are made by joining multiple wythes together. Builders use headers, which are...

brick cutting techniques

Brick Cuts for Fitting Wall Spaces

Brick cuts help fit bricks into small spaces in a wall. A mason uses a hammer with a chisel-pointed end for basic shaping. The mason strikes the brick with sharp, precise blows. For more exact cuts, a power saw with a water-cooled diamond blade is used. Cut bricks are also named by size. A half-bat is a brick cut to half its original length. A three-fourth bat is cut to three-fourths of its length. These cut pieces help fill gaps and keep the wall pattern aligned. Some cuts are made for...

mortar joints in brick masonry

Mortar Joint Profiles and Brick Finishing

Mortar joints hold brick masonry together and help give the wall strength. They fill the spaces between bricks and support the finished structure. Joint thickness can vary from less than one-fourth inch to more than half an inch, depending on the need and the application. As the mortar starts to harden, workers tool the joints. Tooling means compacting and shaping the mortar. This step improves the look of the brickwork and helps it stand up better to bad weather. Brick masonry can be...

spanning openings in brick walls

Brick Wall Supports for Doors and Windows

Brick wall supports help keep openings for doors and windows stable. These supports hold up the weight of the wall above the opening. The main options are lintels, corbels, and arches. Lintels are the main support used to span an opening. They can be made from reinforced concrete, steel-reinforced brick masonry, or simple steel angles. Lintels are usually easy to install and are often hidden inside the brickwork, so they are not visible in the finished wall. Corbels provide only limited...

reinforced brick masonry

Steel-Reinforced Brick Wall Construction

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types of building stone

Building Stone Uses and Rock Types

Building stone is a natural construction material cut from rock deposits and shaped into the sizes needed for building work. It is grouped into three main rock types: igneous, sedimentary, and metamorphic. Each group has different properties that make it useful for specific parts of a structure. Igneous rocks form when magma or lava cools and solidifies. Granite is a common example. It is durable and resists weathering, so it works well in parts of buildings that face severe weather. <br...

quarrying of stone

Stone Extraction and Block Shaping

Stone extraction and block shaping begin in a quarry, where large blocks are removed safely and efficiently. Quarry workers may use controlled explosions, but they also use precise cutting and drilling methods. The goal is to separate stone from the rock face without damaging the material. One common method uses a diamond belt saw to make a vertical cut in the quarry face. The blocks can be very large, sometimes about 50 feet long and 12 feet high. After the cut, workers drill at the base of...

stone masonry

Stone Masonry Types and Jointing

Stone masonry is a building method that uses individual stones to form structures. It is usually divided into two main categories: rubble masonry and ashlar masonry. Rubble masonry uses uneven, naturally shaped stones. These may be river rocks or fragments from quarries. A mason often has to choose each stone carefully and may shape it to fit the space, even when the stones differ in size and form. Ashlar masonry uses stones that are cut into square or rectangular shapes. This type creates...

manufacture of concrete masonry units

Concrete Block Curing and Block Types

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laying concrete masonry

Building a Concrete Block Wall

Building a concrete block wall starts with careful base preparation, mortar placement, and block alignment. The area where the wall will be built is cleaned first. Then mortar is spread where the first row of concrete blocks will sit. The first blocks are often set at a corner to mark the wall boundaries. Mortar is placed on the face shells of the blocks, which are the outward-facing surfaces. It is also applied at the ends of each block. This helps form the vertical joints between blocks and...

steel manufacturing

Steel manufacturing turns iron ore into steel through several controlled stages. It starts in a blast furnace, where iron ore is layered with coke and crushed limestone. The coke is a fuel, and the limestone helps remove unwanted material from the molten metal. Air is blasted into the furnace, and the coke ignites. This produces carbon monoxide, which reduces the iron ore to pure iron. As the iron melts, limestone forms slag. Slag traps impurities such as silica, phosphorus, and alumina. The...

structural steel products

How Structural Steel Shapes Are Made

Structural steel shapes are made in a structural mill. The process starts with a beam blank. The steel is reheated and then sent through a series of rollers that gradually form it into its final shape. The spacing between the rollers can be changed to make different sections with the same nominal dimensions. After shaping, the steel leaves the mill as a continuous length. A hot saw then cuts it into manageable pieces. The cut pieces are cooled and passed through another set of rollers. These...

steel fastening techniques

How Steel Sections Are Joined

Steel sections are joined with rivets, bolts, or welding. Each method fits different structural needs and working conditions. These fastening techniques help assemble strong steel structures in practical ways. Riveting uses cylindrical steel fasteners with a specially designed head. The rivets are heated until white-hot and then placed through pre-drilled holes in the steel sections. A pneumatic hammer shapes the exposed end into a second head, which locks the pieces together. Bolting is...

mechanical characteristics of steel

Testing Steel for Strength and Toughness

Steel is tested for strength, toughness, and flexibility using several standard mechanical tests. These tests help show how steel will behave in real use. They also help engineers choose steel for the right job. A tension test measures tensile strength. In this test, a steel specimen is pulled in a gripping device until it breaks. The results are used to draw a stress-strain curve. That curve shows the proportional limit, yield point, ultimate strength, and the point of rupture. A torsion...

key terms and concepts

Follow the main stages of steel manufacturing, from blast furnace smelting and slag removal to basic oxygen refining, alloying, and continuous casting.

From Iron Ore to Shaped Steel | JoVE K12

JoVE Core Civil Engineering provides a foundational exploration of essential construction materials in civil engineering, focusing on bricks, stones, steel, wood, and concrete through easy-to-understand animated videos. This collection covers the properties, manufacturing processes, and practical applications of these materials. Additionally, the accompanied science-in-action videos demonstrate the research experiments performed in laboratories.

civil engineering

From Iron Ore to Shaped Steel

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