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Improved control of inclusion chemistry and steel cleanness in the ladle furnace
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Improved control of inclusion chemistry and steel cleanness in the ladle furnace

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The objective of the project was to enhance the control of inclusion chemistry and steel cleanness at the end of the refining process by defining the most appropriate operating conditions. This was achieved by evaluating the effects of different operating parameters on inclusion composition, modification, flotation and entrapment in the metal and slag. A second output was the development of a new more general method to interpret metallurgical reactions and processes from measured and analysed data. The goal was achieved by first performing a thorough investigation of the practice at the participating steel plant. This investigation consisted of a detailed mapping of the LF-process at each involved steel plant. The mapping of operation practice included extensive sampling and analysis for the definition of standard conditions in terms of inclusion characteristics during standard operating practices for selected steel. The analyses provided number, size and composition of inclusions together with slag compositions and temperatures. The mathematical simulation models that were used in the project included models describing fluid flow, arc heating, thermo-dynamics and inclusion growth/removal. For these simulations, extensive computational fluid dynamics codes that are able to handle fully three-dimensional fluid flow were used. In addition, process simulations using dynamic mechanistic models (Aspen Custom Modeller) were used to compare flow effects on a microscopic scale (such as those determined with CFD) with macroscopic mixing of the system. The selected models were modified and linked together to enable a study of the LFs of the participating steel plants. The linking between the chosen fluid flow models and the arc heating model made it possible to describe the temperature distribution in the LF as a function of time and enabled a study of local hot spots with high temperature gradients. Existing plant models for physical modelling of the relevant multiphase flow conditions of the fluid dynamics in the LF weres modified to enable the modelling of the involved steel plants. The linked mathematical models describing fluid flow, arc heating and inclusion growth/ separation, together with thermo chemical models and physical modelling, were then used for the evaluation of operation practice in the LF at the participating steel plants. The physical modelling performed provided basic fluid dynamic information on the LF process for evaluation of operation practice. These simulations described how stirring times and heating practice affects the final result in terms of number of inclusions and temperature distribution in the ladle, leading to recommendations for modification of operation practice. The suggested modifications of operating practice were tested continuously to ensure that the predicted improvements were realistic. Extensive sampling was therefore necessary. These extensive plant trials and simulations were then used to propose ways and means to achieve optimum operating practices, which are different for each involved steel plant, for the LF-process. The design of these practices and the greatly enhanced knowledge and understanding regarding all parts of the LF-process are the result of the project.
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ISSN 1018-5593
ISBN 978-92-79-09947-2
DOI 10.2777/14722
Catalogue number KI-NA-23593-EN-S
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ISSN 1018-5593 ISBN 978-92-79-09947-2 DOI 10.2777/14722 Catalogue number KI-NA-23593-EN-S
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