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Foundries that cast steel into commercial products mainly employ coreless induction furnaces or electric-arc furnaces for melting scrap.
Last year, several containers of Indian steel were stopped at European ports after monitors detected high radiation levels; Indian foundries had fabricated the steel, partly, by melting scrap metal that turned out to be contaminated with Cobalt-60, the same radioactive isotope detected in the Mayapuri episode.
A major recycler of scrap metal, Nucor produces steel by melting scrap in electric arc furnaces.
In 1969 Nucor began aggressively expanding minimill production, a far more efficient and less capital-intensive way of melting scrap in an electric-arc furnace.
In a typical charge, the steel mill mixes shred with H.M.S., or heavy melting scrap — large structural pieces, sheared into four-foot lengths, piles of which could also be seen in the yard — layering the heavy melt and shred like sliced potatoes and diced onions in an au-gratin casserole.
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They recycle and melt scrap metal to make parts.
In a mini mill, you melt scrap in electric furnaces, and you could easily fit four of them in this room.
Since there was no cooling effect from inert nitrogen gas present in air, any heat not lost to the off-gas could be used to melt scrap added to the pig-iron charge.
Taking its place, right next door, is a five-year-old minimill that melts scrap steel and produces almost as much as the old one at a fraction of the cost.
Donning a hard hat and a flame-retardant jacket, Mr. Obama toured the plant, chatting with company and state officials amid the roar, sparks and heat of an 85-ton blast furnace and massive machines firing orange-hot, 18-foot steel cylinders made from melted scrap.
But two-thirds of American steel is now produced not in integrated mills but in smaller "minimills," most of them non-union and located in the South, in places like Mississippi County, where the ancient process of using coke to melt iron ore has been replaced by a method in which electricity is used to melt scrap that is then made back into steel of various forms.
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