Steelmaking Research Overview

October 29, 2012

Multi-faceted

Approach to

Solving

Steelmaking

Problems

Scope of Proposed Work (Proposed Research Method)

Industry Needs (Problem formulation)

Multi-scale Modeling (model)

Lab Experiments (data)

Industrial Trials/Validation (process, product)

Optimization Studies (industry data/parameters)

Modeling tools for steel processes Thermodynamic

METSIM

CFD

0

20

40

60

80

100

1300 1350 1400 1450

Temperature (C)

Au

ste

nite

(%

)

15

17

19

21

23

Cr

in liq

uid

(%

)

Liquid (equilibrium)

Liquid (Scheil model)

Cr in liquid (equilibrium)

Cr in liquid (Scheil model)

FACTSAGE

Process simulator

Phase equilibrium

Solidification

Refining

Inclusion chemistry

FLUENT

Molten steel flow

Energy

Multi-phases

Inclusion flotation

Macro-kinetics

Mass balances

Process analysis

Process design

Experimental

Metal casting lab with 200 lb IF

Automated SEM/EDS ASPEX Analysis

Mechanical tests

Thermal simulator

Levitation melting

10 LB VIF

1. New Continuous Steelmaking Process

Modeling

METSIM

1510

1530

1550

1570

1590

1610

1630

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

time (minutes)

ste

el

tem

pera

ture

(ºC

)

2750

2780

2810

2840

2870

2900

2930

2960

2990

ste

el

tem

pera

ture

(ºF

)

proposed continuous steelmaking conventional batch operation

LMF refining

tundish

mold mold

tundish

EAF

3-step refining

EAF

tap &

transport

transport &

sitting on turret

Energy Savings:

- less time and less heating in EAF

- no tapping into colder ladle

- no transport

- no holding

Lab experiments Industrial measurements

CFD FLUENT

Process parameters

Process design

2. Cleanliness of cast steel

0

0.0002

0.0004

0.0006

0.0008

0.001

0.0012

0.0014

0.0016

0.0018

0.002

Furnace, before

deoxidants

Furnace, after

Al

Ladle, after Ca Final Casting

Fra

cti

on

of

Inclu

sio

ns

Others

CaS

MnO

CA

Al2O3

MnSiO3

MnS

oxides

oxides

oxides

oxides

sulfidessulfidessulfidessulfides

0

0.01

0.02

0.03

0.04

0.05

0 0.01 0.02 0.03 0.04 0.05 0.06

Incl

usi

on

s fo

rme

d, w

eig

ht

%

Ca additive, weight %

Al2O3

MnS

CaS

CACA6

CaO

C3A

CA2

CA

y = -14199x + 28.439

R2 = 0.9597

0

2

4

6

8

10

12

14

16

18

20

0.0006 0.0008 0.001 0.0012 0.0014 0.0016 0.0018

Fraction of Area Covered by Inclusions

Ch

arp

y I

mp

act

Test

Valu

es (

ft-l

bs)

Modeling CFD FLUENT FACTSAGE

SEM/EDX ASPEX

Industrial trials

Improved Properties

Lab/Industrial Experiments

CFD - flow

Thermo-kinetics

METSIM – process model

Industrial measurements and model verification

3. Vacuum Tank Degassing

4. CO2 sequestration using slag Experimental kinetics

METSIM

Process modeling

Process design

5. Energy efficiency of melting steel Industrial benchmarking

Industrial measurements

`

Modeling

Heat balances

Potential Topics/Areas of

Steelmaking Research • Recycling of materials

– evaluation / economic models / reclamation

• New raw material development

– Hi Mn DRI / Reduce C footprint / Post-combustion

• Energy / Environmental / Productivity

– Yield improvement / slag splashing

• Cleanliness / Quality Issues

– Steelmaking / Refining / Casting

• Process development – Melt→Refine→Alloy→Treat→Cast→Roll→Heat-treat→Test