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Paraffin wax (sulfur and phosphorous free)used as carburizer material for low carbon steels(Steel20, Steel3, and Steel 20x) instead of kerosene. Results show 1) Carburized layer by wax is more depth than in case of kerosene for all the three types of steel, e.g. for steel 20x the depths are 1.336 0.001 and 0.98 0.15 mm respectively 2) More homogenized carburized layer by wax than by kerosene 3) Higher hardness carburized layer by wax than by kerosene, for steel 20x (61.5 and 59.5 Rockwell Respectively) 4) Carburized layer by wax contains 0.017 % sulfur and 0.98 % carbon while 0.022 % sulfur and 0.93 % carbon by kerosene 5) No sludge materials residue remain on the steel treated surface as in case of using kerosene 6) Under the same conditions (temperature, pressure, and volume) wax shows shorter time than kerosene to get the same depth of carburized layer 7) Wax is more save than kerosene as poisonous and fire hazard material 8) No corrosion effects on the furnace and its heaters in case of using wax than with kerosene (kerosene contains 0.2 % sulfur).

No problem with the melting of new carbon – free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon – free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life ( ~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron ( contain 5% wax according to Jaleel waxing process) according to HYL costs system.

A method of inhibiting degeneration of direct reduced iron by immersing the iron ore, after it has been reduced, in molten wax for a period of time sufficient for the wax to cover completely the surface of the iron and to enter the pores in the surface of the iron. The iron is preferably in the form of pellets which are conveyed in mesh baskets which are themselves immersed in the wax. The wax is preferably paraffin wax at a temperature of between 110° and 120°C.