Fact-checked by Grok 2 weeks ago

Mill scale

Mill scale is the flaky, bluish-black oxide layer that forms on the surface of steel during hot rolling processes, primarily composed of iron oxides including wüstite (FeO), magnetite (Fe₃O₄), and hematite (Fe₂O₃).^[1] This byproduct arises from the oxidation of the steel surface at high temperatures, typically between 900°C and 1300°C, and constitutes about 1-2% of the steel produced in rolling mills.^[2] With an iron content of approximately 68-72%, mill scale is a valuable secondary resource despite being classified as industrial waste.^[1] The formation of mill scale occurs in multiple stages during steel production: initial oxidation during reheating in furnaces, further layering during multi-pass hot rolling, and final adherence after cooling.^[1] Primary scale is often removed via high-pressure water descaling, but secondary scale persists and must be addressed for subsequent applications like coating or welding, as it can promote under-film corrosion if left intact.^[2] Physically, mill scale appears as a brittle, layered solid with a bulk density of around 5.7 tons per cubic meter and a melting point near 1370°C, making it insoluble in water and non-combustible.^[1] Its chemical composition varies slightly based on the steel grade but generally includes trace elements like silicon (0.61%) and manganese (0.059%), with oil content limited to less than 1% for most recycling uses.^[1] In industry, mill scale is recycled extensively to recover iron, reducing raw material needs and waste disposal.^[2] Key applications include incorporation into sinter or pellet feeds for blast furnaces, briquetting for electric arc furnaces, and as a raw material in steelmaking from scrap via submerged arc furnaces.^[2] Beyond metallurgy, it serves in cement production as a flux, in heavy concrete aggregates, battery manufacturing, pigment production, and even as a catalyst or welding flux.^[1] Globally, millions of tons are generated annually, with transport regulated to prevent liquefaction during shipping, emphasizing its role in sustainable steelmaking practices.^[2]

Definition and Formation

What is Mill Scale

Mill scale is the flaky, oxidized layer that forms on the surface of hot-rolled steel or iron during the manufacturing process, serving as a byproduct of high-temperature exposure to oxygen.^[3] This layer primarily consists of iron oxides and adheres closely to the metal substrate, distinguishing it from other surface residues in metalworking.^[4] As a historical byproduct, mill scale emerged with the development of hot rolling mills in the late 18th and 19th centuries, coinciding with the Industrial Revolution's expansion of iron and steel production.^[5] Early rolling technologies, patented in the 1780s, enabled efficient shaping of heated metal into sheets and bars, inevitably producing this oxide scale as the material was processed.^[6] Visually, mill scale appears as bluish-black, tightly adhering flakes, typically less than 1 mm thick, that initially protect the underlying steel from atmospheric corrosion by acting as a temporary barrier.^[7] However, for subsequent fabrication, painting, or galvanizing, it is often removed, as its brittle nature can lead to underfilm corrosion if left intact.^[8] Unlike hammerscale, which forms during traditional forging by hammer blows on heated iron and often appears as loose spheroidal particles, mill scale results specifically from the continuous pressure of rolling mills on hot steel.^[9]

Formation Process

Mill scale forms primarily through the oxidation of hot steel surfaces exposed to atmospheric oxygen during the hot rolling process. When iron or steel billets are reheated in a furnace to temperatures typically between 1100°C and 1300°C, initial oxidation begins, creating a primary oxide layer that is subsequently removed by high-pressure water descaling before entering the rolling mill.^[1] As the descaled steel progresses through the rolling stands, it is repeatedly exposed to air during inter-pass transfers, leading to the formation of secondary and tertiary oxide scales on the surface.^[10] This oxidation occurs above 900°C, where the steel's high temperature accelerates the reaction with oxygen, resulting in a thin, adherent oxide layer that builds up progressively.^[11] The mechanism involves the diffusion of oxygen into the steel surface and the outward diffusion of iron ions, forming a layered oxide structure through sequential phase transformations. The process starts with the rapid formation of an inner wustite layer, followed by outer layers of magnetite and hematite, though the primary iron oxides involved are detailed elsewhere.^[1] Key factors influencing the thickness and adherence of this scale include the rolling temperature, which determines the oxidation rate—higher temperatures above 1100°C promote faster growth—along with the duration of air exposure between rolling passes, typically seconds to minutes, and atmospheric conditions such as oxygen partial pressure.^[10] For instance, in oxidizing atmospheres with sufficient oxygen availability, scale thickness can reach up to 0.1 mm for secondary scales under standard hot rolling conditions.^[1] Repeated rolling passes play a critical role in enhancing scale development by mechanically deforming and cracking existing oxide layers, which exposes fresh metal surfaces to further oxidation during subsequent exposures. Each pass introduces shear stresses that cause micro-cracks in the outer oxide, widening them from the roll gap entry to exit and allowing oxygen ingress, thereby building multiple, inhomogeneous oxide layers with varying porosity—up to 20% in secondary scales.^[10] This iterative deformation-oxidation cycle is unique to rolling, as it combines high thermal exposure with intense mechanical working, leading to a more adherent and multi-layered scale compared to static heating processes.^[11] In comparison to other hot-working processes like forging or extrusion, mill scale formation in rolling emphasizes dynamic inter-pass oxidation under continuous high-speed deformation, resulting in thinner, more uniform layers due to the shorter exposure times and frequent mechanical disruption, whereas forging often produces thicker, less adherent scales from prolonged static heating.^[12]

Composition and Properties

Chemical Composition

Mill scale is predominantly composed of iron oxides, with a total iron content typically ranging from 70% to 75% by weight.^[13] The primary oxide phases include wustite (FeO), magnetite (Fe₃O₄), and hematite (Fe₂O₃), where wustite often constitutes the largest proportion, followed by magnetite and hematite.^[14] These phases form layered structures on the steel surface, with relative abundances varying based on formation conditions, such as wustite comprising up to 95% in primary scales under certain hot-rolling parameters.^[15] Minor elements in mill scale include traces of silica (SiO₂, typically less than 5%), alumina (Al₂O₃, less than 2%), manganese oxides (from Mn content around 0.5-1%), and other impurities such as calcium, sodium, and chromium, which originate from the base steel composition.^[16] The overall chemical makeup exhibits variability depending on the type of steel produced, such as carbon steel versus alloyed varieties, and post-rolling cooling rates, which influence oxide phase stability and metallic iron inclusions (up to 7%).^[17] Faster cooling tends to preserve more wustite, while slower cooling promotes transformation to magnetite and hematite.^[18] The elemental and phase composition of mill scale is commonly analyzed using X-ray diffraction (XRD) for identifying and quantifying oxide phases like wustite, magnetite, and hematite.^[16] Inductively coupled plasma (ICP) spectroscopy, often in optical emission (ICP-OES) or mass spectrometry (ICP-MS) modes, is employed for precise determination of major and trace elemental contents, including iron and impurities.^[19]

Physical and Chemical Properties

Mill scale exhibits a bluish-black color, characteristic of its iron oxide composition, which provides a distinctive appearance to the oxidized steel surface.^[1] Its structure is layered and brittle, forming thin, flaky sheets that adhere initially to the underlying steel but can spall under mechanical stress.^[20] The typical particle size ranges from 0.1 to 1 mm in flake form, influencing its handling and processing requirements.^[21] Due to its significant magnetite (Fe₃O₄) content, mill scale displays magnetic behavior, allowing for magnetic separation in recovery processes.^[22] The true density of mill scale falls within 5.0-5.2 g/cm³, reflecting the dense nature of its oxide phases.^[23] Chemically, mill scale demonstrates high reducibility, readily converting to metallic iron when exposed to reducing agents such as hydrogen or carbon monoxide at elevated temperatures.^[24] It maintains thermal stability up to approximately 1000°C, beyond which phase transformations may occur, but it remains suitable for high-temperature applications without decomposition under normal conditions.^[1] Mill scale shows slight solubility in acids, such as hydrochloric or sulfuric acid, which facilitates its removal through pickling processes.^[25] In terms of reactivity, mill scale is highly reducible and serves as a source of iron oxides in high-temperature metallurgical processes, where the oxides are reduced to metallic iron using reducing agents.^[26] On steel surfaces, it provides temporary corrosion protection by acting as a barrier against atmospheric oxidation until intentionally removed for further processing.^[27] Evaluation of mill scale properties often follows ASTM standards, such as ASTM A380 for assessing scale adhesion and removal efficacy during descaling of stainless steel, ensuring quality control in steel production.^[28]

Production and Handling

Generation in Steel Mills

Mill scale is generated primarily in steel mills during the hot rolling processes of billets, slabs, and blooms into finished products such as sheets, plates, and sections. The key generation points include hot strip mills, where slabs are rolled into thin strips; plate mills, which produce thicker plates for heavy applications; and section mills, which form structural shapes like beams and channels. This occurs specifically during billet reheating in furnaces, the multi-pass rolling stages, and the subsequent cooling phase, where oxidation of the steel surface leads to scale formation as detailed in the formation process section.^[1]^[20] Global annual production of mill scale is estimated at 10-20 million tons, representing approximately 1-2% of the total rolled steel output worldwide. For instance, with global crude steel production exceeding 1.8 billion tons annually, the yield from hot rolling operations aligns with this range, though specific estimates vary based on reporting; one study pegs it at about 13.5 million tons per year.^[29] The yield of mill scale is influenced by several operational factors, including steel throughput rates, which directly scale production volume with output; mill efficiency, where optimized reheating and rolling practices can minimize excessive oxidation; and cooling methods, such as air cooling versus water quenching, with the latter potentially reducing adherent scale through descaling but increasing loose flake generation during rapid temperature drops.^[1]^[30] Historically, mill scale generation has increased in tandem with global steel production growth since the 1950s, when worldwide output was around 189 million tons, expanding to over 1.8 billion tons by the 2020s—a roughly tenfold rise driven by industrialization and demand in construction and manufacturing.^[31]^[32]

Collection and Processing

Mill scale is primarily collected from steel rolling mills through a combination of mechanical and hydraulic methods to capture the oxide flakes and particles dislodged during hot rolling. Mechanical techniques include scraping the scale from rollers and collecting it at the base of rolling stands and conveyors, where it accumulates as the hot steel contracts and sheds the layer. Water flushing is commonly employed on cooling beds to dislodge and transport mill scale via high-pressure sprays, directing it into flumes or pits for settling. Additionally, vacuum systems equipped with powerful pumps are used to suction heavy mill scale particles, particularly in areas with fine dust or to minimize airborne contamination. Magnetic separation is often integrated into these processes, especially for recovering scale from flume water or wastewater, leveraging the material's inherent magnetism to attract and isolate iron oxide particles.^[33]^[13]^[34] Following collection, initial processing prepares mill scale for storage or reuse by addressing its variable form and moisture. The material, often in brittle flakes ranging from microns to several millimeters, undergoes crushing to break down larger pieces for uniformity, followed by sieving to classify particle sizes and remove oversized debris. Drying is essential to reduce moisture content, which typically ranges from 4% to 7% after water-based collection but can reach higher levels depending on handling; this step prevents issues like liquefaction during transport and ensures the moisture stays below the transportable moisture limit. These processes are conducted in settling tanks or dedicated facilities adjacent to the mill to minimize material loss.^[2]^[33]^[35] Quality control during processing focuses on contaminant removal to meet reuse standards, as mill scale can carry oils, greases, or dirt from lubricants and cooling fluids. Washing with water or solvents effectively strips soluble contaminants, while magnetic purification further isolates pure oxide fractions from non-magnetic impurities. The magnetic properties of mill scale, primarily due to its magnetite content, aid in this separation by allowing efficient extraction without chemical additives. Processed material is then sampled and analyzed to ensure low oil content (typically below 1%) and consistent particle distribution.^[2]^[33]^[13] Challenges in mill scale collection and processing include managing fine dust particles that can become airborne or lost during handling, necessitating enclosed systems or filters to capture them. Ensuring minimal loss during transport is critical, as the material's high density and potential for moisture-induced clumping can lead to inefficiencies or safety risks like cargo liquefaction in bulk shipments. These issues are mitigated through integrated recovery systems, but variability in mill operations often requires site-specific adaptations.^[2]^[33]^[35]

Industrial Uses

In Iron and Steel Production

Mill scale plays a crucial role as a recycled feedstock in iron and steel manufacturing, leveraging its high iron oxide content of approximately 70% to serve as an alternative to primary raw materials.^[36] In electric arc furnaces (EAF), it is commonly processed into briquettes and added to the melting charge, providing an iron-rich supplement that reduces the need for scrap metal and enhances furnace efficiency.^[2] Similarly, in basic oxygen furnaces (BOF), mill scale briquettes function as a secondary coolant, replacing iron ore while maintaining process stability in the converter.^[37] The primary method for reclaiming iron from mill scale involves a reduction process where the oxide layer is heated with carbon monoxide or hydrogen at temperatures ranging from 650°C to 950°C, converting it into metallic iron.^[36] This carbothermic or hydrogen-based reduction can achieve metallization degrees exceeding 85-90%, yielding high-purity reduced iron suitable for further steelmaking.^[38] In practice, tilting rotary furnaces facilitate this without pre-agglomeration, allowing integration directly into steel mill operations.^[38] Beyond direct furnace applications, mill scale is incorporated into sinter plants at levels up to 5% of the charge mix to improve sinter strength and productivity for blast furnace feed.^[36]^[39] It also supports pelletizing processes by acting as a feedstock additive, enhancing pellet quality for blast furnace use.^[2] Additionally, mill scale contributes to ferroalloy production, serving as a raw material in the manufacture of ferro-phosphorus and ferro-molybdenum, thereby closing the loop in alloy steelmaking.^[2] Recycling mill scale into these processes yields significant economic advantages, including reduced raw material costs—up to 40% savings compared to traditional scrap usage in induction furnaces—and lower waste disposal expenses, promoting sustainable steel production loops.^[38]

In Refractory Materials

Mill scale, primarily composed of iron oxides, serves as a valuable raw material in the production of granular refractories due to its ability to introduce controlled porosity that facilitates the escape of gases during casting and preheating processes, thereby enhancing the thermal shock resistance of the final product.^[1] This porosity helps mitigate internal stresses caused by rapid temperature changes, making the refractories more durable in high-heat environments such as industrial furnaces. The iron oxide content also contributes to the formation of spinel phases, like hercynite (FeAl₂O₄), which further improve crack resistance and overall structural integrity.^[40] In magnesite-chrome and alumina-based refractories, mill scale is incorporated at levels typically ranging from 5% to 15% by weight to boost the iron oxide concentration, promoting better bonding and chemical stability without requiring expensive synthetic additives. For instance, in magnesite-chrome compositions, mill scale acts as a flux to form ceramic bonds at operating temperatures, enhancing resistance to erosion and peeling.^[41] Similarly, in magnesia-hercynite refractories (an alumina-influenced variant), additions of 7-16% mill scale, combined with magnesia and aluminum sources, yield materials with cold crushing strengths up to 95 MPa after firing.^[40] The manufacturing process involves mixing mill scale with primary aggregates like magnesia or alumina, along with binders such as sodium silicate or graphite, to create a slurry or pellet form, followed by shaping into bricks or castables and firing at 1550-1650°C for 1 hour to achieve densification and phase development.^[40]^[41] This approach offers a cost-effective alternative to synthetic iron oxides, recycling steel industry waste while producing refractories suitable for steel ladle linings, where they demonstrate performance comparable to commercial products in terms of strength and slag resistance.^[40]

In Powder Metallurgy

Mill scale, a byproduct rich in iron oxides, is converted into reduced iron powder through thermochemical reduction processes suitable for powder metallurgy applications. The primary methods involve hydrogen reduction in a tube furnace or carbon monoxide reduction in a fixed bed reactor, typically conducted at temperatures ranging from 900 to 1100°C for durations of 120 to 180 minutes. These processes yield sponge iron powder with a metallic iron content exceeding 95% Fe, often reaching up to 98.4% purity after annealing to minimize residual carbon and oxygen levels to below 0.3%. The resulting powder exhibits a porous structure with particle sizes generally between 50 and 150 μm following grinding and sieving, making it ideal for subsequent compaction.^[24]^[42] The reduction achieves a high degree of metallization, typically 95-99%, corresponding to an iron recovery yield of 80-90% from the original mill scale, comparable to or surpassing traditional direct reduced iron (DRI) processes that typically yield 90-95% metallization using coal or syngas.^[43] Post-reduction, the sponge iron is milled to uniform particle distribution and tested for chemical composition, apparent density, and flow rate to ensure compliance with Metal Powder Industries Federation (MPIF) Standard 35 specifications for structural powder metallurgy parts, which define minimum purity, particle size, and mechanical property thresholds. This standardization facilitates consistent performance in downstream processing.^[44] In powder metallurgy, the reduced iron powder from mill scale is pressed into green compacts at pressures of 400-800 MPa and sintered at 1100-1300°C in a controlled atmosphere to form dense metallic components. Key applications include automotive gears, oil-impregnated bearings, porous filters, and structural bushings, where the powder's high purity and porosity enable superior sinterability and mechanical strength, such as tensile strengths exceeding 40 ksi in alloyed variants. These parts leverage the cost-effectiveness of mill scale as a recycled feedstock, reducing reliance on primary iron ores while maintaining properties comparable to commercially produced atomized powders.^[42]^[45]

Other Applications

In Cement and Construction

Mill scale serves as a valuable source of iron oxides in cement production, where it is added to the raw mix for Portland cement clinkers, typically in small amounts to supply the required iron content of about 2-5% in the final clinker composition.^[46] This addition facilitates the formation of key clinker minerals, such as alite and belite, during the high-temperature sintering process in rotary kilns, while also contributing to the characteristic gray color of Portland cement.^[47] By providing high-purity iron oxides (>70% Fe content), mill scale integrates seamlessly into the kiln feed after screening and blending, ensuring uniform distribution without prior grinding to avoid segregation.^[48] One key benefit of mill scale in cement kilns is its role as a fluxing agent, which lowers the melting temperature of the raw materials and enhances burnability, thereby reducing energy consumption and improving overall process efficiency.^[46] Furthermore, incorporating mill scale recycles a steel industry byproduct, minimizing the extraction of virgin iron-bearing minerals like hematite or pyrite and supporting circular economy principles in cement manufacturing.^[48] Beyond cement production, mill scale finds application in construction as a partial substitute for fine aggregates in concrete mixes, where it acts as a dense filler to boost durability and mechanical performance.^[49] Research indicates that replacing 10-40% of sand with mill scale increases concrete density, compressive strength (up to 20-30% improvement in some formulations), and resistance to chloride ingress and water absorption, making it suitable for self-compacting or high-strength concretes in corrosive environments.^[50] Recent studies as of 2025 confirm its use in sustainable mortar formulations, enhancing post-fire properties and durability.^[50] Since the 2010s, cement plants in India have increasingly adopted mill scale to align with sustainability goals, driven by rising steel production waste and regulatory pressures for resource efficiency; for example, Indian facilities have explored its integration to offset growing exports of unused scale.^[51]

In Art and Pigments

Mill scale contributes textural elements in metal sculptures and patinas, where its flaky, bluish-black surface creates rusty, metallic effects that enhance the industrial aesthetic of artworks.^[52] For instance, sculptor Richard Serra preserved mill scale on steel plates in works like Delineator (1974–75), using its grainy patina to contrast smooth surfaces and activate spatial perception in minimalist installations.^[53] This approach aligns with broader 20th-century trends in process art, where unrefined byproducts like mill scale symbolized the grit of modern manufacturing.^[53] Preparation for artistic use involves milling raw mill scale to micron-sized particles—often under 50 microns—for optimal dispersion, followed by mixing with binders like linseed oil to form stable paints or patina accelerators.^[54]^[55] During grinding, artists must employ ventilation and protective masks, as inhalation of fine mill scale dust can irritate respiratory tracts and pose long-term health risks similar to other iron oxide particulates.^[56]^[57] Recent research (2020–2024) has explored mill scale as a source for inorganic pigments in ceramics, such as in stoneware tableware and dark pigments via calcination, supporting sustainable applications in art and design materials.^[58]^[59]

Recycling and Environmental Impact

Recycling Methods

Mill scale, a byproduct rich in iron oxides, is primarily recycled through direct reintegration into steel production processes to recover its metallic value. One common method involves briquetting, where fine mill scale particles are compacted with binders such as molasses or organic agents into dense briquettes suitable for charging into electric arc furnaces (EAFs) or blast furnaces. This approach enhances handling and reduces dust loss, allowing up to 90% of mill scale to be recycled directly within steel mills.^[36]^[60] Pelletizing represents another key technique, blending 10% mill scale with iron ore fines and binders to form green pellets that are indurated for use in sintering plants or direct reduction processes; this substitution improves pellet strength and productivity without compromising metallurgical properties.^[61]^[36] For producing iron powder, chemical reduction methods are employed, often using hydrogen gas in a controlled atmosphere at temperatures between 650°C and 950°C. Mill scale is first ground to under 75 μm and briquetted, then reduced in a rotary kiln or thermo-balance setup, achieving high reduction efficiencies that increase with temperature and gas flow rate; this yields metallic iron powder for applications in powder metallurgy.^[36]^[62] Advanced recycling processes target higher purity outputs. Hydrometallurgical leaching dissolves iron oxides from mill scale using acids like hydrochloric acid (HCl) or sulfuric acid, producing pure iron salts such as ferrous sulfate heptahydrate or ferric chloride (FeCl3); for instance, two-stage leaching with HCl recovers iron chloride solutions that can be further processed, minimizing impurity dissolution.^[63]^[64] Emerging plasma arc recycling utilizes high-temperature plasma torches (up to 15,000°C) in cupola furnaces to vitrify and reduce mill scale alongside other wastes, generating high-purity iron outputs with low slag formation; recent pilots (as of 2025) explore hydrogen-enhanced plasma for lower energy use, though commercial adoption remains limited due to energy intensity.^[65]^[66]^[67] Globally, mill scale recycling aligns with regulatory frameworks promoting resource efficiency, such as EU waste directives. In Europe, approximately 1.3 million tons of mill scale are generated annually (as of 2025, estimated as ~1% of EU steel production), with logistics involving bulk shipping from mills to recycling facilities to facilitate large-scale reintegration. Recycling mill scale offers energy savings of up to 74% compared to primary iron production from ore, primarily by avoiding mining and beneficiation steps.^[19]^[68]^[69]

Environmental and Economic Considerations

Recycling mill scale plays a crucial role in reducing landfill waste, as global production reaches approximately 20 million tons annually (as of 2025, estimated as ~1% of global crude steel production), much of which could otherwise contribute to environmental burdens if discarded.^[70]^[1] This practice diverts significant volumes from disposal sites, promoting sustainable waste management in the steel industry. Additionally, utilizing mill scale in place of virgin iron ore lowers CO2 emissions, with savings estimated at 1.5 tons of CO2 per ton recycled, akin to the benefits observed in steel scrap recycling.^[67] Economically, mill scale holds value as a byproduct, with market prices typically ranging from $50 to $100 per ton based on 2025 estimates influenced by quality, location, and demand.^[7] Steel mills benefit from selling this material, generating revenue that offsets disposal costs and supports operational efficiency.^[71] Under regulatory frameworks, mill scale is classified as non-hazardous waste by the U.S. Environmental Protection Agency (EPA) and the European Union's REACH regulation, facilitating its reuse without stringent hazardous waste protocols.^[72] However, handling requires dust control measures to address inhalation risks from fine particles.^[25] Emerging circular economy policies, such as those promoted by the European Steel Association under the EU Green Deal, further incentivize its recycling to enhance resource efficiency and reduce reliance on primary materials.^[73] Despite these advantages, challenges persist, including contamination risks from oil residues in unprocessed mill scale, which can limit recyclability if exceeding 1% content.^[2] The market for mill scale also exhibits volatility tied to broader steel price fluctuations, driven by supply-demand dynamics and global economic factors.^[74]

References

[1]
Mill Scale - IspatGuru
May 25, 2017 · Mill scale is a layered and brittle material, composed of iron oxides with wustite as a predominant phase. It is normally considered as waste material.
[2]
Generation Transport and Uses of Mill Scale - IspatGuru
Sep 23, 2014 · Mill scale is the flaky surface of hot worked steel and is formed by the oxidation of the steel surface during reheating, conditioning, hot rolling, and hot ...
[3]
Mill scale (ferrous metal) - Substance Details - SRS | US EPA
Definition: The oxidized surface of steel produced during reheating, conditioning, hot rolling, and hot forming operations. This substance is usually ...
[4]
https://www.redlabelabrasives.com/blogs/news/mill-scale-what-it-is-how-to-remove-it
[5]
Historical Development of Rolling Mills - IspatGuru
Jan 24, 2021 · By the late 1700s, the first hot rolling mills appeared, allowing iron to become a more popularly rolled material. The Industrial Revolution ( ...
[6]
History & Interesting Facts of Steel Rolling Mills - Steefo Industries
May 5, 2023 · The first patented rolling mill was invented in 1783 by Henry Cort in the UK. In the early 20th century, rolling mills helped accelerate ...
[7]
Mill Scale: Home
The scale or oxides are like a hard brittle material which is mainly composed of mostly ferric, iron oxides and is generally bluish black in color. Also ...
[8]
Removing Mill Scale from Steel Surfaces - Latem Industries
Jan 21, 2019 · In fact, in the short term, a layer of scale helps to protect the metal's surface from corrosion and other negative atmospheric effects. The ...
[9]
(PDF) A possible medieval recycling technique – smelting iron using ...
Aug 23, 2022 · Hammerscale is a common by-product of the forging process of iron and it may appear in a large amount in the ancient smithy workshops as ...<|control11|><|separator|>
[10]
[PDF] Scale development on steel during hot strip rolling Acciaio - CORE
The paper presents a new method to describe and to predict the development of scale during metal forming processes, especially hot strip rolling processes.
[11]
Thesis | Scale formation and descaling in hot rolling of low carbon ...
Low carbon steel was oxidized in air over the temperature range 600-1200°C for 120 s to approximate the formation of secondary and tertiary scale in hot rolling ...
[12]
[PDF] WHAT IS MILL SCALE? - Dulux Protective Coatings
Mill scale is a type of iron oxide formed on steel during hot-rolling, often mistaken for a blue primer. It is not uniform and can cause corrosion.<|control11|><|separator|>
[13]
Production of cleaner mill scale by dynamic separation of the mill ...
Mar 1, 2018 · The mill scale is mainly composed of iron oxides. Total iron content in the mill scale could be up to 70–75%. Therefore, the mill scale can be ...
[14]
Steel mill scale nanoparticles prepared via high-energy wet milling
Aug 1, 2025 · The steel mill scale is primarily composed of iron oxides, which constitute approximately 94 % of its chemical composition, with phases ...
[15]
Mechanical properties and phases determination of low carbon steel ...
Nov 25, 2015 · Their relative thicknesses (to the total layer thickness) correspond to 95% wüstite, 4% magnetite, and 1% hematite [1], [2], and these values ...
[16]
An Innovative Method of Converting Ferrous Mill Scale Wastes into ...
May 13, 2021 · Chemical composition of mill scale waste. Element, Average Content, wt.%. Fe, 77.06 ± 0.04. O, 13.35 ± 0.15. Ca, 4.50 ± 0.26. Si, 1.90 ± 0.88.
[17]
Overview on production of reduced iron powder from mill scale waste
### Summary of Mill Scale Chemical Composition and Iron Content
[18]
Growth Rate and Phase Composition of Oxide Scales during Hot ...
For the initial 30s of oxidation, wustite was the predominant phase in the temperature range. 800–1 200°C and as oxidation proceeded, the percentages of ...
[19]
Reuse of the Steel Mill Scale for Sustainable Industrial Applications
Dec 11, 2020 · The chemical elements from the steel mill scale sample were determined using inductively coupled plasma. ... mill scale composition are ...
[20]
Millscale - an overview | ScienceDirect Topics
Millscale is a thin layer of iron oxides which forms on the steel surface during hot rolling of the plates and sections.Missing: color | Show results with:color
[21]
Table 3 Particle size distribution of mill scale - ResearchGate
Table 3 shows the grain size distribution of the mill scale, revealing that 70?7% of the accumulated weight presents a particle size of >0?125 mm.Missing: color magnetic
[22]
Structural, Electromagnetic and Microwave Properties of Magnetite ...
This study presents the utilization of mill scale waste, which has attracted much attention due to its high content of magnetite (Fe3O4).
[23]
Physico-chemical Properties of Mill Scale Iron Powders - J-Stage
Feb 15, 2020 · Apparent density is in the range of 2.49–2.56 g/cc and true density is 5.4 g/cc.
[24]
Recovery of Iron from Mill Scale by Reduction with Carbon Monoxide
This article presents results of experiments using the TG/DTA thermal analysis method aimed at verifying the possibility of recovering iron from the mill scale.
[25]
[PDF] Mill Scale - US Steel
2(a) Classification of the Chemical: Mill Scale is considered a hazardous material according to the criteria specified in REACH [REGULATION (EC) No 1907/2006] ...
[26]
(PDF) Study on reducing and melting behavior of mill scale ...
Aug 8, 2025 · The proportion of this formed product depends on the temperature that the reduction takes place. The main chemical reactions during the ...
[27]
Electrochemical Properties of Oxide Scale on Steel Exposed in ...
Oct 8, 2018 · The mill scale originating in the steel production process consists of mainly three types of iron oxides: wustite FeO, magnetite Fe3O4, and ...
[28]
Standard Practice for Cleaning, Descaling, and Passivation of ...
Jan 15, 2025 · This practice covers the standard recommendations and precautions for cleaning, descaling, and passivating of new stainless steel parts, assemblies, equipment, ...
[29]
[PDF] An overview of incorporating steel mill scale in the production of ...
Chemical composition of steel mill scale. The typical chemical composition of steel mill scale includes pre- dominantly iron oxides (Fe O, Fe2 O3 , Fe3 O4 ) ...
[30]
Effect of Accelerated Cooling on Linepipe Steel Mill Scale and ...
Dec 28, 2021 · The structure and composition of mill scale on linepipe steel formed with and without accelerated cooling conditions (ACC) was investigated ...
[31]
[PDF] World crude steel production 1950 to 2006
World crude steel production. 1950 to 2006. (million metric tons). Years. World. 2006. 1,244. 2005. 1,142. 2004. 1,069. 2003. 970. 2002. 904. 2001. 850. 2000.
[32]
World Steel in Figures 2025 - worldsteel.org
Highlights. Steel production has been stable since 2020. Globally, 214.7 kg of steel was used in new products per person in 2024. In tonnes CO2 per tonnes of ...
[33]
Mill Scale Recycling: History & Best Practices - Waste Optima
Sep 12, 2025 · What Is Mill Scale? Mill scale is a bluish-black oxide layer composed primarily of iron oxides (FeO, Fe₂O₃, Fe₃O₄) that forms on the surface ...
[34]
[PDF] INDUSTRIAL VACUUM SOLUTIONS FOR STEEL PLANTS - Delfin
Only a powerful vacuum unit with a lobe pump (reaching 85% of vacuum) can easily collect large quantities of heavy material like the Mill Scale. The ...
[35]
Mill scale and mill scale fines: Liquefaction risk - Skuld
Feb 10, 2016 · It turned out that the Moisture Content (MC) of the cargo in the stockpiles ranged from 4.14% to 7.1%.
[36]
Production of Iron from Mill Scale Industrial Waste via Hydrogen
Approximately, 90% of mill scale is directly recycled within steelmaking industry and small amounts are used for ferroalloys, in cement plants and in the ...
[37]
Development and use of mill scale briquettes in BOF - ResearchGate
Aug 10, 2025 · There has been limited research on the briquetting process of mill scale to reuse in the blast furnace (BF), electric arc furnace (EAF), and ...
[38]
[PDF] Production of reduced iron from mill scale waste using tilting ... - AIST
Reduced iron is produced from mill scale using a tilting rotary furnace (TRF) without pre-agglomeration, and the process can be done in any large steel mill.
[39]
https://www.researchgate.net/publication/268078361_Recycling_of_mill_scale_in_sintering_process_Science_of_Sintering_43_1_pp_21-3_2011
[40]
Refractory - US3240615A - Google Patents
The following examples are illustrative of refractory mixes within the scope of this invention: Example I Parts by weight Periclase 50 Chromite 35 Mill scale 5 ...
[41]
[PDF] Elaboration of iron powder from mill scale
Oxidation at 1000°C converts the iron oxides that are present in the mill scale, FeO and. Fe3O4, to ferric oxide (Fe2O3). Table 1. Chemical compositions of mill ...<|control11|><|separator|>
[42]
Standards - Metal Powder Industries Federation
MPIF standards are intended to present and clarify press & sinter, metal injection molding (MIM), and metal additive manufacturing (AM) technologies to aid in ...Missing: mill scale
[43]
[PDF] Characterization of Iron Powder Produced by Reduction of Hot ...
Feb 12, 2022 · It was reduced to metallic iron powder at temperatures above ... mill-scale and reduced iron powders at different reduction temperatures.
[44]
Mill Scale as an Additive for Cement Use
Mill scale has many industrial uses including manufacturing cement and raw materials for cement clinkers.
[45]
Process for using mill scale in cement clinker production
This mill scale flakes off the steel as it is being formed and contains chemical elements that are necessary in the art of making cement clinker. The mill scale ...
[46]
Mill scale - AEIFOROS METAL PROCESSING S.A
A by-product of the steel production, mill scale is an attractive alternative source of iron oxides for the cement industry and the chemical industry.
[47]
Evaluating the role of steel mill scale in self-compacting concrete as ...
This study evaluated the potential of steel mill scale (SMS), a steel industry byproduct primarily composed of iron oxides, as a partial replacement for ...
[48]
Utilization of Mill Scale Waste as Natural Fine Aggregate ... - MDPI
The particle size distribution of fine aggregates was assessed using sieve analysis following ASTM C136-06 [12]. Figure 1. Mill scale waste at landfills.
[49]
(PDF) An overview of incorporating steel mill scale in the production ...
Oct 10, 2025 · Steel mill scale incorporation produces concrete with high specific gravity and consequently high density, improved mechanical, water absorption ...<|control11|><|separator|>
[50]
[PDF] Engineering Behaviour of Sustainable Concrete with Steel Mill Scale
Oct 16, 2020 · Steel mill scale was replaced in different percentages like 0%,. 20%, 40%, 60%, 80% and 100% respectively. Three numbers of specimens were cast ...
[51]
Transformation of India's steel and cement industry in a sustainable ...
The study concludes that a stringent carbon policy in combination with strong sustainability principles can reduce CO 2 emissions by 68% in the steel and ...
[52]
The Color of Art Pigment Database: Pigment Brown - PBr
The Preparation of Magnetite, goethite, hematite and magnemite of pigment quality from mill scale iron waste. Goethite - (Ref at Mindat.org). Magnetite - ( ...
[53]
Richard Serra Sculpture: Forty Years - The Brooklyn Rail
Sep 10, 2007 · (The plate above—too high to get a strong feeling for—has a different surface because it still has a good deal of its mill scale, a byproduct of ...
[54]
How to Remove Mill Scale: Industrial Coatings - Dustless Blasting
Nov 22, 2024 · This process involves immersing steel in a chemical bath using hydrochloric acid to remove the mill scale. Acid-based solutions, such as ...
[55]
US7347893B2 - Iron oxide pigments from mill scale - Google Patents
Spray roasted red ferric oxide (3 kg) is mixed with pulverized mill scale (6 kg) of a fineness less than 50 microns. The mixture is heated to a temperature of ...Missing: size | Show results with:size
[56]
Characterization of Black Pigment Based on Iron Oxide from Mill ...
Oct 22, 2017 · Mill scale was dried under sunlight then milled to get powder form. Mill scale powders calcined on 800 o C temperature in furnace and kept 2 ...Missing: micron | Show results with:micron
[57]
[PDF] Mill Scale - Section 1 – Identification - Stelco
Apr 8, 2021 · 10(a) Reactivity: Not Determined (ND). 10(b) Chemical Stability: Mill Scale is stable under normal storage and handling conditions. 10(c) ...
[58]
Respiratory Hazards of Making Art - Sentry Air Systems, Inc.
May 8, 2025 · Art materials such as clay can create airborne silica dust that can be harmful if inhaled. Making jewelry and creating metal sculptures can ...
[59]
Briquetting and hydrogen reduction of mill scale using novel binders
Apr 10, 2024 · It is clear that the moisture content significantly decreased, dropping from about 4.6 wt% to a range of 1–2 wt% in all recipes after compaction ...
[60]
Recycling of steel plant mill scale via iron ore pelletisation process
Aug 10, 2025 · The addition of mill scale up to 10% is considered to provide the optimum balance of chemical, physical and metallurgical properties of the ...
[61]
Overview on production of reduced iron powder from mill scale waste
Mill Scale is a by-product of the rolling mill in steel hot rolling processes. It contains both iron in elemental form and three types of iron oxides: wustite ( ...<|control11|><|separator|>
[62]
production of FeCl 3 from iron and steel industry waste (mill scale ...
Feb 17, 2024 · Mill scale (MS) is considered to be a significant metallurgical waste, but there is no economical method yet to utilize its metal content.
[63]
[PDF] Prodution of Ferrous Sulfate From Steelmaking Mill Scale - SciSpace
Mill scale is constituted mainly of iron oxides; the chemical characterization of the mill scale by ICP-AES is meant to give an idea of the chemical ...
[64]
[PDF] Plasma Arc Technology - P2 InfoHouse
the plasma-assisted cupola for iron melting and recycling of mill scale (iron oxide). Applications of Plasma Arcs. The plasma processing of gases, liquids ...
[65]
Process for recovery of iron/steel from mill scales and fines
Some of these processes use plasma arc furnaces, briquetting machines and pelletizing systems. These processes are very expensive, inefficient, and require ...
[66]
Recycling is the primary energy efficiency technology for aluminum ...
May 9, 2014 · The Environmental Protection Agency estimates that secondary steel production uses about 74% less energy than the production of steel from iron ...
[67]
Steel packaging achieves highest recycling rate on record
Jun 6, 2025 · The latest figures from Steel for Packaging Europe reveal an 82 percent recycling rate for 2023.
[68]
PULVERIZED STEEL MILL SCALE WASTE FOR GREEN ...
Sep 19, 2025 · Economic advantages include cost savings on waste disposal [6], generating revenue from reprocessed materials, and enhancing market ...
[69]
Climate change and the production of iron and steel - 2025
Every tonne of steel scrap used avoids the emission of 1.5 tonnes of CO2 and avoids the consumption of 1.4 tonnes of iron ore, 740 kg of coal and 120 kg of ...Missing: savings mill
[70]
Dedicated to sustainable practices in the steel industry
Because liquid pig iron is delivered in a molten state, it introduces productivity gains and cost savings at the steel mill, including a reduction in energy ...
[71]
[PDF] Mill Scale - LIBERTY Steel Group
Mill scale is defined as a waste under REACH and does not meet the requirements for classification as dangerous under the Classification, Labelling and ...
[72]
[PDF] EUROFER Input Consultation on the New Circular Economy
mill scales or dusts. The recycled content measure could be applied, for instance, also to plastic products/materials or to wood products segments. On the ...
[73]
Oily mill scale as an industrial waste: processing and utilization
Recycling (putting into sintering stage) of oily mill scale is impossible due to high content of oil products: up to 10% in oily scale and up to 50% in sludge.<|separator|>
[74]
Steel Industry Volatility, Risks & Risk Mitigation - Vermeulens
The cost of structural steel has been volatile across the United States with steel supply pricing sharply increasing since March 2020.