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An alternative process involving direct reduced iron (DRI) is likely to succeed it, [citation needed] but this also needs to use a blast furnace to melt the iron and remove the gangue (impurities) unless the ore is very high quality.
The blast furnace method is expected to survive into the 22nd century because of its efficient rate of iron production at competitive costs compared with other iron-making methods. Blast furnaces keep on improving with adaptations arising from new technologies driven by rising global demand, yet the main chemical process remains the same.
The process is based around a cyclone converter blast furnace, which makes it possible to skip making the BOS-required pig iron pellets. Skipping this preparatory step makes the HIsarna process more energy-efficient and lowers the carbon footprint .
The preferred method of iron production in Europe until the development of the puddling process in 1783–84. Cast iron development lagged in Europe because wrought iron was the desired product and the intermediate step of producing cast iron involved an expensive blast furnace and further refining of pig iron to cast iron, which then required ...
The basic oxygen steel-making process is as follows: Molten pig iron (sometimes referred to as "hot metal") from a blast furnace is poured into a large refractory-lined container called a ladle . The metal in the ladle is sent directly for basic oxygen steelmaking or to a pretreatment stage where sulfur , silicon , and phosphorus are removed ...
The Chinese are thought to have skipped the bloomery process completely, starting with the blast furnace and the finery forge to produce wrought iron; by the fifth century BC, metalworkers in the southern state of Wu had invented the blast furnace and the means to both cast iron and to decarburize the carbon-rich pig iron produced in a blast ...
This process was gradually succeeded, from the 1st century in China and the 13th century in Europe, by the blast furnace, which simultaneously reduces and melts iron. [ 3 ] Elaborate low furnaces, such as the tatara or the Catalan forge , survived until the early 19th century. [ 1 ]
The Bessemer process was the first inexpensive industrial process for the mass production of steel from molten pig iron before the development of the open hearth furnace. The key principle is removal of impurities from the iron by oxidation with air being blown through the molten iron.