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--etve the property lghis 10 this document which cannot be reproduced DAWIELI 8 &, LADLE METALLURGICAL FURNACE BASIC OPERATING INFORMATION THE INFORMATION CONTAINED IN THIS BOOK, HAS BEEN PREPARED TO GIVE THE OPERATOR SOME BASIC KNOWLEDGE ON HOW TO OPERATE THE LADLE FURNACE. FOR TECHNICAL INFORMATION, REFERENCE SHOULD BE MADE TO THE USE AND MAINTENANCE INSTRUCTION MANUAL OF THE PLANT CONCERNED. OPERATORS OF THE LADLE ee Lethe FRREQUIRE SOME METALLURGICAL rev. date description issued checked approved 00 29 December issue Hi.Cook GDiMise, ‘LMaestroni anim Service @ TRAINING Center © paneeu service Training Center CONTENTS LADLE REFINING STATION DESIGN CONSIDERATIONS LADLES PROCESS DESCRIPTION SECONDARY REFINING HEAT CYCLES FOR GRADES 1010 AND 1040 PROCESS EXAMPLE, REASONS FOR NOT HITTING AIMED ANALYSIS a) Nitrogen b) Sampling ©) Slag in Ladle Furnace 4) Deoxidation e) Alloying f) Heating 8) Gas Stirring h) Desulphurisation OPERATORS MANUAL - Heating - Thermal Efficiency + Electrical characteristics + Selection of operating points + Slag Composition + Stiming PRODUCTION CONTROL LF FUNCTIONS OF PROCESS CONTROL SYSTEM FORMATION OF ELECTRODE COLUMNS SAMPLING DIRECT / INDIRECT LRdoe 2164 Se DANIELI SERVICE Training Center DUTIES OF PERSONNEL WIRE FEEDING * SLAG RAKE AND OPERATIONS * DESULPHURISATION DEOXIDATION PRECIPITATION AND DEOXIDATION SILICON-MANGANESE DEOXIDATION * VACUUM-CARBON DEOXIDATION * SLAG CHEMISTRY - DESLAGGING - BACKGROUND DESLAGGING METHODS - EQUIPMENT * SLAG MAKING / DEMANDS ON SLAG SLAG MAKING IN THE L-F / SLAG CONSTITUENTS + ADDITION OF LIME/FLUORSPAR « TEMPERATURE / STIRRING / CARBON & SILICON CONTENT OF STEEL STIRRING / IN GENERAL STIRRING METHODS Induction = Gas stirring / examples = Comparisons INDUCTION STIRRING IN THE L-F PROCESS - Equipment = Operation - Examples / Desulphurisation « HOMOGENISATION - ALLOYING LRdbe 3164 Se DANIEL SERVICE Training Center EFFICIENT MIXING FOR SATISFACTORY RESULTS OXYGEN REMOVAL ALAND SILICON LOSSES EXAMPLES OF L/F OPERATIONS. - Steelmaking - Pulpit Control Leos 8 DANIELI SERVICE Training Center LADLE REFINING STATION The secondary treatment facility from DANIELI / CENTROMET consist of a Ladle Fumace unit with auxiliary equipment. All these production facilities are equipped with the best and latest technologies available on the market, developed from many years of experience. ‘The Ladle Fumace transformer, operating points and reactance symmetry are calculated to achieve the most efficient heating capability’s without excessive refractory wear and excessive use of slag builders, Efficient and accurate electrode positioning control is ieved by using hydraulic individual electrode regulation in combination with a fast digital regulator, The operating costs for the Ladle Fumace is kept low due to the above reasons as well as developed and proven process control system, with features 2s calculating and optimising the alloy addition based on cost and updating of the process times to avoid unnecessary delays disturbing the process flow. After years of experience, the optimal equipment, parts and design of auxiliary systems are used in order to assure a high reliability of the supplied units. The Ladle Furnace station is easy to operate by means of a sophisticated computer control system including process control as well as equipment control, using the latest technologies in MMI, Man Machine Interface, with well proven and easily available software. Together with this philosophy and the use of well proven equipment, the maintenance will be easy and low in cost, and the availability factor high. Design considerations The secondary refining unit, the ladle furnace, is designated and dimensioned with high enough capacity to handle all the heats supplied by the arc furnace, and to meet with the sequences as the caster. Special attention have been paid to: © Productivity © Product quality * Low maintenance and operation costs As one of the main tasks, from productivity point of view, of the ladle furnace, is to act as a buffer between the arc furnace and the caster, its treatment capacity must be considerably higher than that for the other two units, Also if the tap-to-tap time is varying in the are fumace, the secondary unit must have the capacity to make up these variations and still catch up with the sequence at the caster. The cycle time in the heating station must be low enough, and thus the heating rate optimised to reach this goal. The dimensioning of each unit is discussed separately below: LFdoe 5164 Se (GANIELI SERVICE Training Center Ladles The lining type, Alumina, Magnesite or Dolomite, should be discussed and agreed upon during the technical discussions. For the start-up period, the Alumina lining is to be prefered, being less sensitive to temperature fluctuations, while for continuous production, from metallurgical point of view, a Dolomite or Magnesite lining could be advantageous, giving lower oxygen contents. p con The operation schedules for two typical steel grades, 1010 and 1040 have been computer simulated, The attached time-temperature diagrams show the total cycle from tapping of the primary furnace, refining in the secondary refining units until reaching the right composition and temperature for casting, For standard treatments, valid for these steel grades, the main operations after the primary furnace treatment, are: 1. Slagftee tapping with additions of deoxidisers, recarburisers and some alloying, Part of the slagbuilders are added for insulation purpose . Transport to the heating station . Arriving to heating station, temperature measurement |. Slagbuilder addition Slagmelting, homogenisation Temperature increase Sampling / Alloy additions . Temperature and composition correction, inclusion removal, wire feeding, if applicable 9. Temperature measurement 10.Timing to meet the schedule of casting SIAM RYR The assumed cycles are illustrated overleaf, The diagrams show in the upper part the temperature evolution throughout the entire ‘treatment, In the lower part of the diagram are indicated the fundamental operations, where the letter “T’ within a circle means a temperature measurement and ‘S’ means steel sample, LFdoe 6/64 eS DANIEL! SERVICE Training Center Heat Cycle Steel Grade 1010 for 80 t Ladle Furnace Temperature, ‘F Temperature, °C 3,100 3,000 +} 2900 Tig 2788 °F 2200 11884 °C) og a7 2700 = Time, mins ‘Treatment time 25-28 min [EATING HEATING fslagmak. 50 7005 7.0507 TOE] CI si = [isi on | [3 om) Ist og Hn 0.30 |jHn 0.43 | [mn 0.43 iMn 0.45 P 0.03 ||P? 0.03 | 3p 0.03 |e 0.03 | s_0.03 }{s_0.03 | js 0.03 | |3 o/oe UF doe 7164 4.600 4,380 1,500 © paneeu service Training Center Heat Cycle Steel Grade 1040 for 80 ¢ Ladle Furnace “Temperature, ‘F ‘Temperature, °C [nig 2750 "F (1810 °C) Tig 2730 F (1499 °C) L 3 i eae T 7 7 i 1 Time, mins ‘Treatment time 25-28 min . 39 i: sit Si 0.11 | /st oa Nn 0.50 j! Hn 0.71 |] Mn 0.71 Ie 0103 |: 0.03 |}r 0.03 1S 0.03 j,s_0.03_}/s__0.03 LFdoe 8/64 8 DANIELI SERVICE Training Center Process example: During tapping of the primary furnace an initial addition of ferroalloys is performed to deoxidise and alloy the steel, For insulation purpose, some of the slag builders are added at the end of tapping, to cover the bath surface. As the primary furnace, being an EBT fumace, can tap practically slagfree, no destagging is normally necessary. After tapping the ladle is transferred, Bubbling is performed during all operations in the secondary treatment stations. The first heating period will last until the slag is fused, the steel analysis is uniform and the steel temperature is high enough to enable good sampling, While waiting for the sample analysis, heating is continued and main alloying additions are given as soon as the laboratory analysis is received. The temperature is increased to the aim temperature before casting. A short final bubbling period might be added for homogenisation reasons. During this period, wire feeding could be performed, for steel ‘grades needing wire additions, Treatment of steel according to the illustrated heat cycle, for the grades 1010 and 1040, occupies the heating station for about 25-28 minutes. The consumption of materials and utilities is largely a function of the active process time, Experiences from several steetplants indicate that it is economically advantageous to reduce the primary furnace tapping (emperature as much as possible, in order to utilise the available process time in the heating station for active heating, The illustrated heat cycle with actual heating during less than 20 minutes in the heating station at a power of 10-12 MW gives an energy consumption of around 45-50 kWh per short ton of steel. Additional waiting in the heating station for coordination with the caster, if any, adds energy consumption to this figure. Leos 9164 Se DANIEL! SERVICE Training Center REASONS: FOR NOT HITTING AIMED ANALYSIS ‘To much slag from primary fumace Rephosphorisation Lowalloy yield High oxygen potential To large alloy addition in first batch ‘Wrong calculation Reduction from primary furnace slag (P, Mn) Weighing error Steel sample taken to early Alloys left in the slag when sampling Inhomogenous melt (short stirring time) Low Temperature Alloys teft on conveyor from previous heat NITROGEN (N2) <> 2(N) I From atmosphere and alloys Wl Increased N pick up at low O and S content WN pick up is fast in the arcs MN pick up when stirring with No LRdoe 10/64 © vaneeu service Training Center SAMPLING I Sample shall be homogeneous and representative of steel melt Simple and rapid sampling procedure Quick sampling preparation Reliable and reproducible results Sample design shall fit chemical analysis equipment Reasonable price for probe SLAG IN LADLE FURNACE I Basic slag (% CaO / %SiO2 = 2-4) Hl Reducing slag Cover bath surface and ares (approx 100 mm) Non aggressive to refractory (MgO) Fluid LRdoe nes 8 DANIEL SERVICE Tralning Center DEOXIDATION WE 2(A) + 30) == (AhO:) MH Deoxidation: reduce dissolved oxygen in metal bath by adding alloys with high affinity to oxygen (c.g. Al, Si, SiMn, CaSi) WH Removal of deoxidation products (Al20s, SiOz, MnO SiOz) by gentle stirring at end of treatment. WE Vigorous stirring can cause reoxidation WE Oxygen leakage from: Stag Refractory Atmosphere Alloys a ALLOYING Additions made on open steelbath Deoxidizers Carbon Ferro alloys Slagbuilders Start Heating Stirring continuously LPdoe 12/64 e DANIEL! SERVICE Training Center ALLOYING Ml Gas stirring increases dissolution rate and reduces the risk for undissolved alloys in the slag WM Ifthe start temperature is low, avoid alloying from start (especially carbon) WE Alioys with low density (FeSi, C) have difficulties in penetrating the slag WH First addition: aim for minimum analysis specification depending on size of addition, analysis range, precision HEATING I Heating with electrodes to: ‘Compensate for heat losses Make fluid and reactive slag Compensate for cooling effect of additions Heat steel to teeming temperature Il General heating practice: Maximum allowed power in shortest possible time MH Temperature check during heating Ledoe 13/64 8 DANIEL! SERVICE Training Center HEATING WH Parameters influencing heating Stirring all the time Heating with little or no slag gives: Carbon pick up Increased electrode consumption Increased energy consumption Increased refractory wear Low power input, unstable arcing MH Long aros reduces Carbon pick up but increases reftactory wear WH Mett slag as quickly as possible Wf Premixed slag melts faster GAS STIRRING @ PURPOSE FLOW RATE Wl Desulphurization high HH Alloying high HH Removal of inclusions low WH Heating to increase temperature high / moderate to maintain temperature moderate Ros 14/64 Se DANIEL! SERVICE Training Center STIRRING WE Distribution of heat from bath surface to bulk HE Homogenisation of steet composition ME Removal of inclusion WH Slag-metal reactions Facilitate alloying, sampling, wirefeeding oe DESULPHURIZATION (CaO) + 2/3 [Al] + [S} => (CaS) + 1/3 (ALOs) (CaQ)+1/2(Si]+(S] <=> (CaS) 1/2 (SIO) (CaO) + [Mn] + [S} ==> (CaS) + 1/3 (MnO) I Basic slag (CaO) ME Fluid slag WE Low oxygen potential in steel (well deoxidised) WH Stirring Slag volume LRdoe 15/64 eS DANIEL! SERVICE Training Center DESULPHURIZATION Thermodynamics: What is possible ? IS) @02-) [8] Ls= —- = Ks [%s] (f$2-) [a0] a Ledoe 16/64 Se DANIEL! SERVICE Training Center Operators Manual, Secondary Refining Introduction ‘The use of secondary refining has increased dramatically in the last decade, Ithas been found that certain metallurgical processes can most efficiently be carried out in a specially designed vessel after the primary furnaces. Processes have been developed which provide various refining techniques such as: * Improved methods of alloy addition. The steel composition and consequently also the final product performance is controlled within more narrow ranges. Expensive alloying elements can be saved * Synthetic slag practice for desulphurization, deoxidation and improving inclusion removal * Pneumatic injection of Ca or Ca components for desulphurization or inclusion modificaiton * Ca or CaSi wire injection for inclusion modification © Vacuum degassing for hydrogen, nitrogen and carbon removal and desulphurization to very low content * Decarburization of stainless steel, AOD type converters and VOD Most of these operations call for additional heating of the metal after the primary fumace. Excess heat is only produced in the processes for decarburization of stainless steel, The by far most economical process for additional heating after the primary furnace is arc heating in the ladle. Other methods, plasma heating, oxy-fuel burners or oxidation of Al or/and Si with oxygen has both economical and quality draw blacks. ‘An are heated heating station offers more benefits than the already mentioned, namely: © The primary furnace can be used exclusively for the process it is designated for resulting in far less tap to tap time * The tap temperature can be decreased. Shorter tap to tap and less energy and refractory consumption ‘© The heating station can be used as a buffer. Longer sequences in the continuous caster is possible ‘The Centro-Met/Danieli secondary refining systems are designed with standardized modules selected to give the best performance for each individual steel plant, LF doe 17/64 Se DANIEL! SERVICE Training Center Heating Engery input is necessary for refining reactions, composition and temperature control. Are heating in the ladle must be carried in such a way that unwanted reactions like carbon and gaseous pick up are minimized. This must be combined with high energy yield, low refractory wear and low electrode consumption. The main parameters for heating are slag volume, slag composition, stirring, electrode current and secondary voltage. Selection of an operation point, secondary voltage and electrode current, must consider: slag thickness risk for refractory wear risk for carbon pick up from the electrodes the thermal efficiency Thermal efficiency The thermal efficiency is defined as the net power supplied to the melt related to the active power measured on the primary side of the furnace transformer TE = (W* Cp * DI/Dt* 60 * .001)P where TE = _ thermal efficiency, % w = steel weight, 100 kg Cp = _ heat capacity, kWh/_(1000 kg, 1 °C) DIDt = heating rate, °C/min P= _ active power, MW or TE = (P-Ple-PityP where Ple = _losses in the power supply system Plt = _heat loss from the steel and the are Fee 18/64 (c} DANIEL! SERVICE Training Center Furnace Electrical Characteristics ‘The working range of a furace transformer is defined by the rated power in MVA and the maximum secondary current, Most transformers have an overload capacity ranging from 0 up to 30% depending on the used average capacity. nominal power active power power factor electrode current secondary voltage cos f*S, furnace resistance furnace reactance furnace impedance SQRT (RY2 + K"2) are power electrode voltage are voltage Ie * Uare U/SQRT 3 Uelec - voltage drop Are length Refractory index Pare * (Uare - 35) /a2 Uarc = Selection of the Operating Points A furnace operating point can be defined as a certain transformer secondary voltage combined to a certain electrode current. This also means a certain arc power and arc length. ‘The operating point must be optimized for each heating application. The suitable amount of slag for the refining process and the risk for and consequences of carbon pick-up must be considered. ‘The are should be submerged in the slag which calls for an are length 20 mm shorter than the slag depth, This is more important than the refractory index. ‘The minimum arc length must be chosen to minimize the risk for carbon pick up. The exact value must be established for each installation since the stirring characteristics are very important. A gas stirred system should in most cases have an arc length of at least 65 mm. The are length can be some 20 mm shorter when using inductive stirring, Loe 19/64 Se DANIEL! SERVICE Training Center The power factor, cos @, should be selected to get as much power as possible to the steel. Too high power factor can cause problems with unstable arcing conditions. It is recommended to chose operating points with power factors below some 0.85. The thermal efficiency is improved when working with high power input. It is better to use onoff practice when heating compared to a low power input if the steel must be held for a long time in the heating station, Slag composition The arcing conditions is to some extent controlled by the slag chemistry. CaQ/SiO2 ratios less than 2.5 should be avoided. ‘This is not in conflict with the metallurgical performance except for the resulphurized grades. A high CaO/Si02 ratio makes it difficult to control the sulphur content. Stirring Arc heating without simultaneously stirring the bath does not work properly. The concentrated heat supplied by the arcs must continuously be absorbed by and distributed in the steel bath. The stirring must be optimized for each heating and refining reactions. Strong stirring should be used when adding materials and when good refining results are important. Medium stirring should be used when heating to equalize the temperature gradients in the system. Gentle stirring should be used at the end of the treatment, Steel grades sensitive for gaseous pick up should be stirred without exposing the steel to the atmosphere. LR doe 20164 Se DANIELI SERVICE Training Center Production control L-F © Communications © Functions * Production scheduling * Analysis registration * Data base management © Alloy calculation ‘© Slag builder addition Energy balance calculation Byent and heat reports General Arrival Heating Injection Departure System structure Electrode adjustment Operating modes: standard manual automatic LPdoe Function of operator interface Instruments Man machine interface Ladle Movement Central hydraulic unit Argon bubbling Supervisor functions Files management Manufacturing instructions Material information 21/64 ic) DANIEL! SERVICE Training Center Functions of process control system Steel grades Heat report Process routes Chemical analysis estimate Final grades Additives addition management Process steps Aduitives addition modalities Analysis formula Casting report Steel analysis coefficient data Consumption report Slag analysis data Allowed materials Yield data Operator instructions Heating data Calculation parameter register Material information data Process supervision Alarm acquision Ferro Alloy calculations Lrdoe 22.64 Se DANIEL! SERVICE Training Center Formation of electrode columns Electrode on the ground in horizontal position, Remove from the electrode the protection cap of the threaded part Check the thread - worms must be in good condition Clean inside with compressed air - make sure that air is dry and without oil Introduce the sheél metal funnel, by screwing it manually and completely . Hook to the EOT crane the manual device, signal to the crane operator and bring it to ‘match the funnel . Hook the manual device to the funnel and lock it to the funnel itself . Signal to the crane operator and slowly lift the electrode avoiding that the low end is scratched at ground, inserting some sof material (i.e,polystyrene end cap) 8. With the electrode in vertical, move the EOT crane to the station with clamp of the nippling station 9. Insert the electrode into the open clamp, lower it and stop the lowering when the funnel is at about 500 mm from the clamp - lock the clamp. The threaded part of the electrodes must never concem the tightening clamp, because the threaded part could be damaged 10.Unhook the manual device, release the EOT crane and unscrew the funnel from the electrode 11.Bring the funnel to match the second electrode and repeat the operations 1-5 12.Clean and screw at the other end a nipple repeating the inspection and cleaning as per points 1-2-3, also clean the nipple 13.Screw the nipple (sometimes electrodes come with the nipple inserted) 14.Repeat the operations described in points 5-6-7-8 15.Center the electrode suspended to the EOT crane with the one locked in the clamp 16.Lower with a great care the electrode and fit the nipple into the threaded seat (using the wishbone spacer) 17Rotate the electrode suspended to the EOT crane and gradually lowering, sorew it on the one locked by the clamp 18.Screw until the space between the two electrodes is reduced to approx. 15-20 mm 19,Check that into the space there are no pieces of electrode or foreign matters; if so, clean with compressed air 20.Continue to screw manually until the contact of the two electrode surfaces 21.Then, lock with the torque wrench, calibrated at the required value according to the electrode diameter 22.Repeat the operations of points 10-21 for the third electrode ypeene ao LF doe 23164 @ panieu seevice Training Center Remark: The preparation of joints is a rather delicate operation and, if it is not carried out correctly, important damages as the breakage of the junction and the consequent interruption of the productive process might rise. Therefore, it is necessary to carry out an accurate cleaning of the electrode seats and faces using compressed air, only if strictly necessary, because of pre-existing dirt, use a metal brush, then blow out again. The poor connection of joints can cause bad quality electric conductivity and therefore hot and weak joints. Too loose electrode: - slackness - poor electric loading Too tight electrode: + cracks ~ breaks Ledee 24164 e DANIEL! SERVICE Training Center Handling and jointing tools Many electrode manufacturers have designed special tools which can be supplied on request. Below, the main operations necessary to prepare the electrode columns are listed; these must be performed in the special position for electrode preparation, Graphite lifting plug: the graphite lifting plug can be left into the socket of the top electrode of the column as a protective device. There is no risk of splitting the socket wall due to the expansion of the lift plug. Alternate designs are also available. ‘Threaded attachment: the threaded attachment has the advantages that, once the threads are engaged, the jointing operation can be completed without further crane movement. Tightening wrench: it is important that the correct torque be used when tightening joints, To some extent, this depends on whether a ‘on-furnace’ or a ‘off-furnace’ procedures are used. In the case of a ‘on-furnace’ jointing, some form of wrench must be used to apply the torque manually. “Off-furnace’ jointing can be performed either mechanically or manually,. Off-fumace assembly is generally performed under better working conditions. For manual application of torque, there are several designs of wrenches which are easily ‘manufactured or available from tool suppliers. Lrdoe 25/64 eS DANIELI SERVICE Training Center Substitution of electrode columns on the furnace This system is planned for the substitution of the electrode columns on the fumace when the consumed column has become too short, The necessary operations for the correct use of the devices, to make possible the column substitution are listed as follows: 1, Put the furnace into safe condition and open the main switch 2. Put the furnace in vertical position . Give instructions to the crane operator and hook the automatic device to the EOT crane hook . Give instructions to the crane operator about the column to be replaced . The crane operator hooks the column and put the ropes under a slight tension . Open the electrode-holder clamp . Withdraw the column and move it to the nippling station . Insert the column into a pipe with clamp and lock it . The crane operator hooks a ready column and brings it to the furnace 10.The column is inserted into the clamp and locked at the height decided by the furnace operator 11.The crane operator releases the automatic device 12.The furnace can start operating again 13.A piece of electrode will be added to the removed column, when the temperature will allow it, by following the instructions: preparation of electrode column PEI awE Leee 26164 8 DANIEL! SERVICE Training Center Sampling In the following, we shall classify the different sampling methods according to: a) Idirect sampling. Melt is taken with a spoon and then poured into a sample mould, or the sample is sucked from the spoon into an evacuated glass tube. b) Direct sampling. The sample is taken directly from the meli with a thickwalled tube mould (‘bomb sampte’), lollipop mould or a suction sample. Indirect sampling Sampling is carried out using a spoon which should be covered with slag before it is dipped into the steel bath. The molten steel is then poured into a mould, or an evacuated glass tube is dipped into the spoon. There is also pin sampling apparatus equipped for suction by pistol, or suction ball. Disposable evacuated glass tubes are most often used for combustion analysis of carbon and sulphur, but are also used for gas analysis of hydrogen, nitrogen and oxygen. This is discussed in the next section. Moulds intended for top-filling with a spoon may be constructed of many different materials: precision-cast copper moulds, massive-cast iron moulds or graphite moulds. The simplest one is a solid copper mould giving a conical sample about 80 mm long and 20-35 mm in circumference. The sample is cut straight across for a suitable area for spectrometrical analysis, This type of mould has a long life and is cheap. When used, this has to be combined with suction-tube sampling for rapid analysis of elements like carbon and sulphur. Other types of top-filled moulds of the disc-pin type have been developed. The sample mould is of the disposable type and may give a disc sample as well as a pin sample suitable for carbon and sulphur analysis, The disc sample must be ground 0.5 mm on the surface before chemical analysis. Steel composition, temperature, slag viscosity and degree of deoxidation play important roles in the final result using top filled moulds. The validity of carbon content analyzed in the top-filled mould sample is not always good enough due to carbon segregation into the surface, This is most accentuated by high carbon steels, For carbon analysis, the suction glass tube is said to be the most representative. Pre-evacuated glass tubes have also shown themselves to be best with regard to homogeneity, porosity and slag in samples. Lider 27164 e DANIELI SERVICE Training Center Direct sampling Sampling is done direct into the steel-melt. The samples may be of disposable or reusable type, bottom or top-filled. Top-filled moulds have shown that they do not meet the demands made on sampling for production control (insufficient degree of filling, porosity, low percentage of acceptable samples, complicated sample preparation, etc. A steel mould can be used for repeated sampling. The top is covered with a cardboard lid preventing slag penetration. This sample can be used for spectrometrical as well as oxygen analysis. Duties of personnel Duties of personnel are generally consistent with the organization Chart that gives the relationship of various job-post holders in a given working department. They are also generally consistent with the plant and production technology and with the basic concepts adopted for the work division. Duties and responsibilities are not defined and assigned once for ever. They may be changed depending on changeable conditions, among which the increasing work experience and capability of the involved personnel. The duties, responsibilities, lines of authority and reporting to the various levels and job-posts are described in a company document designated as job-descriptions, These jjob-descriptions are given for reference and understanding only. They do not represent ‘any limitation to different assignments the company might decide upon. Loe 28/64 Se DANIEL! SERVICE Training Center WIRE FEEDING Operation Preliminary Prepare the wire coil on the support of the machine and thread the wire end into the rolls groove, Feed the wire manually by means of the proper push button, until it crosses all the pairs of guide and idler rolls and appears from the guide curved pipe above the ladle. Wire injection into the bath Preset on the machine, through the appropriate programmer, the wire meters to be fed; the preset value will appear on the display of the machine; preset the injection speed. When the preset quantity of meters has been reached, the machine stops automatically. At this point, using the proper pushbutton, make the wire go back to avoid blocking the ladle route. Coil in emptying phase Always be careful about the coil, which must never be finished completely because besides the coil also the rolls could be emptied and the wire could remain in the curved ladle pipe; so, when there are only few meters to finish the coil, the machine is stopped and the-wire is retreated so as to remove the coil from the support and replace it with a new one, If for the reason mentioned above, the wire feeding is interrupted, immediately charge a new coil on the support and inject the needed wire meters. LFdoe 29164 Se DANIEL! SERVICE Training Center Slag rake description and operations General information ‘The slag rake serves to remove the primary furnace slag from the ladle. Description The slag rake is hydraulically operated by hydraulic motor, chain and sprocket; the front part of the beam is water cooled. The forward and backward movement of the arm is realized by electric motor. ‘An open control cabin permits the rotatory and longitudinal motion of the rake. ‘The removed slag is discharged into a pot located below the ladle edge. Operation When the ladle is inclined and after verification of slag to be removed, by operating the arm forward and backward, it is possible (o carry out the deslagging operation in a few minutes. After the completion of this operation, the ladle should be brought back to the horizontal position and then to the reheating station, with gas stirring or induction stirring in progress all this time. During these phases, itis opportune, in order to prevent the porous plug to be blocked to maintain a certain Argon flow-rate in the gaseous stirring system. Leos 30/64 Se DANIEL! SERVICE Training Center Desulphurizataion The removal of sulphur can be done at different stages and in different ways during the making of iron and steel. Some are more efficient than others. In today’s “secondary steelmaking” desulphurization occupies an important position. This is due to the high efficiency which it is possible with existing facilities, with increasing demand for extremely low sulphur content in the final steel, the present “secondary” equipment is, as a matter of fact, the only way to meet these requirements, particularly with regard to steel made from scrap. In the Ladle Fumace four main methods can be appli Steel-slag reaction at atmospheric pressure Steel-slag reaction at reduced pressure (vacuum) Steel-slag reaction combined with addition of rare earth metals Steel-slag reaction combined with injection of desulphurizers “Steel-slag” reaction is referred to as the interplay between the steel bath and the slag cover. The reaction, in this case the removal of sulphur, takes place in the interface between the two phases, steel and slag. It is a matter of continuously renewing or exchanging this contact layer in order to transfer the sulphur from the melt to the slag. Chemically the reaction can be described as follows: (CaO)slag + [S]steel <> (CaS)slag + — [O]stecl “Fresh” lime must always be available at the interface to take care of the sulphur rich steel which must continuously be brought up to the same territory, And this is not all. The newly-formed compound of lime and sulphur, CaS, has to be removed simultaneously from the reaction area, just as the “relieved” oxygen [O] has to be “neutralized” by added deoxidizers such as aluminium, silicon, etc. Thus transportation of the reaction agents, (CaO) and [S] to, and the formed reaction products, (CaS) and [0] from the “battlefeld”, plays an important role in this business. This transportation is greatly facilitated by stirring. Another must important factor is the distribution of sulphur between the steel and the slag, (S)(S]. Efficient sulphur removal implies a high value of this ratio. To sum up, efficient sulphur removal needs the following prerequisites: ‘A. Highly basic slag, ie. a basicity, CaQ/SiO2, of 2 3.5 B. Low oxygen content, ie. about 10 ppm, in the steel (corresponding to about 0.1% FeO in the slag) C. Large contact area steel-slag to reduce the transportation distances D. Efficient stirring . E. Large slag volume LF doe 31/64 8 DANIEL! SERVICE Training Center Of the four desulphurization methods mentioned earlier, the first one is the slowest while the last one is the quickest and the cheapest. It should be observed that all the above five factors must be fulfilled in order to achieve maximum results, “Normal” operation of the Ladle Furnace, i.e. using arc heating and gas stirring, and with the above conditions satisfactorily met, gives a sulphur removal of about 60-80%. If, for instance, the sulphur content is 0.040% on arrival at the Ladle Fumace unit, it can without any special arrangements be lowered to 0.015-0.020%. Even if the slag volume is increased. It is hardly possible to obtain a better result without introducing argon blowing under vacuum or in an inert atmosphere. By blowing gas, a vigorous mixing of slag and steel is obtained which will provide good kinetic conditions for the slag to bind sulphur. To secure a good result, it is advisable to put the whole system under vacuum or to introduce an inert furnace atmosphere, in order to prevent oxidation of the steel which is liable to exposure to the atmosphere due to the eruptions caused by the blown gas. The oxygen content in the whole system must under all circumstances be kept low. When dealing with desulphurization, the “finishing touch” can be added by applying the injection technique. This involves injection of deoxidizers and desulphurizers in powder form into the melt. That is to say that instead of only working with a “blanket” of slag containing lime and having a low oxygen content, the slag-forming and the deoxidizing agents are mixed into the melt, thereby creating an immense contact area with the steel, The injection can be carried out with a lance, passing through the vacuum lid or at a special station adjacent, to the existing deslagging, heating and vacuum stations. By combining some or all of the possibilities mentioned the mode of sulphur removal can thus be chosen at will. The Ladle Furnace is, in other words, also extremely versatile in this respect. LF doe 32164 Se DANIEL! SERVICE Training Center Deoxidation Introduction Depending on steelmaking practice and type of steel, at the time of tapping steel contains 80-200 ppm O2. In pure liquid: iron the oxygen solubility varies with temperature according to the formula. log (% O) = - 6320/T + 2.734 Inall steelmaking processes, the oxygen content of the steel is high when the total iron oxide content of the slag is high. As given by the formula, liquid pure iron saturated with iron oxide contains 0.23% oxygen at 1600 °C or 0.16% at the melting point 1527 °C. During solidification the oxygen solubility decreases rapidly and as oxygen is almost insoluble in solid iron or steel, the oxygen dissolved in the melt has to combine with other elements in the bath. Oxygen plays @ significant role in steel, forming either blowholes or non-metallic inclusions in the ‘final cast steel product. The aim of deoxidation is to decrease the final total oxygen content in the solid steel. One of the key reactions in steelmaking is the carbon oxidation in liquid steel. [C] + [0] <--> {co} For carbon contents below approx. 0.5% the carbon-oxygen equilibrium product depends on the pressure in accordance with [%C] [0%] / PCO = -1168/T - 2.07 For 1 atm pressure of carbon monoxide and at 1600 °C the solubility product of [%C] [%O] is 0.002. Results from practical steelmaking and comparison with equilibrium data are given in figure 1. Depending on steel practice for 0.2% carbon in solution the steel contains 100-200 ppm oxygen at 1600 °C. Leos 33/64 @ paneeu seevice Training Center ° OF O8 12 46 20 at Carbon, we% FIG.1 The relation between the carbon and oxygen contents of molten iron in equilibrium with carbon ‘monoxide at various pressures (from Marshall and Chipman 103) For further deoxidation and for avoiding blowhole formation during solidification there are in principle three methods of deoxidation: a) Precipitation deoxidation - addition other elements to the melt with strong oxygen affinity, thus forming deoxidation products (non metallic inclusions) which are supposed to be partly separated in the melt or during solidification, b) Vacuum carbon deoxidation - decreasing the total pressure over the steel surface, thereby decreasing the partial pressure of carbon monoxide. The carbon monoxide ibrium according to the formula given above can also be changed by purging gs with low partial pressure of carbon monoxide through the melt, ©) Diffusion deoxidation - bringing the liquid: steel into contact with a liquid slag having a lower oxygen potential than steel, thus causing a transfer of oxygen from steel to slag. Diffusion deoxidation is very time-consuming and mostly of theoretical interest. It will not be dealt with here. Ledoe 34/64 Se DANIEL! SERVICE Training Center Precipitation and Deoxidation Depending on the carbon and particularly the oxygen content of steel, the ingots cast without any complementary deoxidation will contain more or less blowholes because of gas evolution during solidification. Killed steel is deoxidized to such an extent that no g0s evolution occurs during solidification. Deoxidation is performed by adding ferro- alloys of manganese or silicon or by using stronger deoxidizers such as aluminium calcium etc. Semi-killed steel does still have enough oxygen present to form some carbon monoxide gas in spite of deoxidation with silicon or manganese added in smaller amounts than for killed steel. Killed steel is generally used when a homogeneous structure is wanted in the finished product such as for alloy steel. Although the oxygen dissolved in liquid steel is lowered to a few parts per million immediately after addition of the deoxidizer the total oxygen content can remain rather high due to sluggish separation of the oxide inclusions formed at deoxidation and during solidification. This is shown schematically in figure 1. Three steps in deoxidation can be distinguished: a. Formation of nuclei of the deoxidation product b. Flotation and separation ¢. Growth of the reaction products According to figure 1 the first step occurs very rapidly due to very high local supersaturation at the time of addition of the deoxidizer - the time for lowering the dissolved oxygen from 100-200 ppm to a few ppm after addition is in the order of one minute. ADDITION DISSOLVED OXYGEN Figure 1 Loe 35/64 Se DANIEL SERVICE Training Center The further rate of progress of deoxidation depends on the time which is available to separate the inclusions that is growth, flotation and separation to lining and slag ot during casting and solidification, to mould walls and top of the ingot. Growth and separation of the oxide products in the melt is accomplished within 10 to 30 minutes is achieved by stirring. At the same time, it is essential that the steel melt is protected against reoxidation. This can be done by covering the steel bath with a basic slag and having an inert atmosphere. In practical steelmaking the equilibrium oxygen content will not be reached due to reoxidation and incomplete separation of deoxidation products, that is the total oxygen content analyzed in somewhat higher than oxygen in solution, measured by oxygen sensors, Precipitation deoxidation may be performed in the primary furnace before tapping or by adding into the tap-ladle approximate amounts of deoxidizers. During further ladle refining final deoxidation and composition adjustment may be carried out. The most commonly-used deoxidants are silicon, manganese and aluminium, From figure 2 it can be seen that oxygen in solution in liquid steel at 1600 °C varies greatly dependent on the element added. In all cases given the oxygen and solute are in equilibrium with the appropriate gas or solid oxide phase. gear ‘aor a ‘ eo % Ledoe 36764 Se DANIEL! SERVICE Training Center Silicon-Manganese deoxidation Although silicon is a stronger deoxidizer than manganese, deoxidation is usually carried out using both these elements, Above a critical ration (%Mn)/(%Si) the deoxidation product consists of liquid manganese silicate, see figure 3. When the deoxidation product formed is saturated with silica, only solid silica forms, In the manganese/silicon composition range above the curves, manganese does not take part in the deoxidation reaction, Practical experiments have shown that growth and separation of liquid silicates takes place much faster than that of solid silica or partly-solid manganese silicates. The beneficial effect of manganese on the oxygen solubility in a liquid steel of 0.1% C at 1650 °C after simultaneous deoxidation with silicon and manganese is shown in figure 4. DEOXIDATION™™ ‘PRODUCT. SOLIO SILICA’ SILICON, we OXIDATION ProvucT: ‘MOLTEN, (MANGANESE ‘SILICATE ° 025 ‘080 076 10 MANGANESE, wt Figure3 - Equilibrium relations for deoxidation of stel with silicon and manganese at 1600 C (CTurkdogan 235) a sant oa a oar 10 SATURATED wiTHsOID 80, oxveenmns MoLTINSICEATE a [sxumnomscuomerngt : (UC a Figure 4 doe 37/64 e DANIEL! SERVICE Training Center Vacuum-Carbon Deoxidation The effectiveness of vacuum-carbon deoxidation depends on the formation and growth ‘of gas bubbles in the melt. One condition for carbon monoxide gas evolution to occur is that the partial pressure of CO is sufficiently low according to the reaction [C] + [0] <> The bubble pressure, PCO is determined by the chamber pressure Pa, The pressure given'by the head of melt (ferrostatic pressure) pf and by the bubble surface tension Pb PCO = Pa+Pf+Pb Po = 2sir 8 = bubble surface tension r= bubble radius In order to get a bubble growth the solute content in the bubble melt has to be sufficiently high to sustain the required excess pressure of the bubble. Bubble nucleation occurs primarily on the refractory lining. At low pCO values carbon is a stronger deoxidizer than silicon and manganese, However, theoretical equilibrium values are not achieved. The C . Q product normally corresponds to an equilibrium CO pressure of 50100 tor. Once the growth of the bubble has been established, other solutes such as hydrogen and nitrogen are flushed out of the melt. Degassing by purging argon gas during vacuum treatment enhances the CO degassing by lowering the carbon monoxide partial pressure. Normally, strong killed steel can not be vacuum-carbon deoxidized. Experiments have shown for different treatments in Ladle Furnace ladle for 1% C steel that: a. A vacuum treatment after pre-deoxidation with ferrosilicon during tap and proper aluminium deoxidation in ladle does not further lower the final oxygen content in the ‘melt, Aluminium determines the oxygen solubility , A vacuum treatment immediately after pre-deoxidation with ferrosilicon during tap without aluminium addition provides a lowered oxygen content but not as low as that achieved by aluminium deoxidation, ¢, Aluminium deoxidation combined with long and intensive stirring results in the lowest oxygen contents achieved. This is independent of vacuum treatment. During vacuum-carbon deoxidation alone there will be some loss of other elements in the steel bath, Manganese will vaporize due to relatively high vapour pressure and there will also be some reduction of oxides in lining, slag and inclusions. Loe 38/64 eS ‘DANIEL! SERVICE Training Center Slag Chemistry Deslagging Background ‘The reasons for preventing the primary fumace slag from entering the ladle furnace are: + Minimizing phosphorus reversion into the steel - Minimizing the amount of oxygen entering the ladle furnace - Limiting the lining wear The primary furnace slag contains more or less phosphorous pentoxide. P:Os bound to the lime as calcium phosphate. ‘The P content depends on the raw material used in the primary furnace. Clean scrap and/or reduced pellets (sponge iron, made from pure ore) give hardly any phosphorus in the steel (or in the slag) made in the arc fumace. The same goes for the converter, when using high-grade hot metal made from low phosphorus ore. The extremity on the high side is converter steel made from high phosphorus hot metal (containing about 1.8% P). Between these two levels there is great variation of P contents in stee! and slag. The content of phosphorus pentoxide in the slag can vary from less thall 1% to more than 20%. The acceptable amount of slag entering the ladle furnace is thus, amongst other things, dependent on the phosphorus level in the slag, ‘The crude steel leaving the primary furnace is in general oxidized, The oxygen content is a function of the carbon level. Since there is a relationship between the oxygen content in the steel and in the slag respectively, this means that the furnace slag can be more or less aggressive to the refractory lining. The oxygen exists in the slag as iron oxide, FeO, fluxes, MgO and CaO, which are the main constituents of the refractory lining, The more of this slag coming into the ladle furnace, the greater is thus the risk of lining wear. This type of slag also has a negative effect on the yield of added alloys, especially those having a strong oxygen affinity, such as silicon, aluminium, titanium, vanadium, etc. Since alloys are expensive it is important to restrict the consumption of these materials as much as possible. Thus it is important in most cases to minimize the quantity of furnace slag entering the ladle furnace, : On the other hand there are examples where large slag volumes are desirable in the ladle furnace, i.e. when desulphurizing. This is in general fulfilled by adding adequate amounts of lime. If, however, the P content in the primary furnace slag is sufficiently below the “critical” level, itis possible to let this slag, or at least part of it, remain in the ladle furnace to take part in the subsequent refining (desulphurization) which will take place there. LPdoe 39/64 eS DANIEL! SERVICE Training Center Deslagging Methods In practice the slag during primary melting, for instance in an are furnace, is allowed to run off during the final stage of melting. At this stage the slag usually contains a high iron oxide content. After tapping into the ladle the steel is normally pre-deoxidized but it still contains a high oxygen content and the oxygen potential of the slag is high. In order to prevent the primary furnace slag from entering the ladle furnace there are three ways to deslag: © Deslagging of the primary furnace before tapping # Reladling © Deslagging of the ladle before starting the treatment Reasonable deslagging of the primary furnace is possible in the case of an arc furnace, especially if this is equipped with an induction stirrer, and also to some extent in the case of converters. Of these three possibilities, reladling is without doubt the most efficient. Reladling ‘means that the steel is tapped from the primary furnace into a transport ladle, which is then teemed through a nozzle into the ladle, By observing the metal stream leaving the nozzle, the latter can be closed as soon as slag is starting to mingle with the steel. If, however, some “primary slag” is tolerated in the ladle furnace. The most rational method is to draw it off from this vessel before starting the treatment, The latter method is less costly than reladling and more production-saving than deslagging the arc furnace. Slagging-off the ladle furnace calls for: * Possibility of tilting the ladle # Slag rake * Slag spout Bath movement Tilting of the ladle can be done cither with the aid of the crane or by placing it in a tiltable cradle, At present only the latter is used. The modem ladle cars have made it possible to tilt the ladle in the ladle car and thereby provide for very simple deslagging. This deslagging possibilty is very valuable, since it shortens the time in the melting fumace, which leads to increased production, It is also makes it possible to obtain the desired slag coriposition in the lade furnace, which is particularly important when desulphurization is called for. The slag rake can be mechanized or operated manually. Both versions are used. A slag spout is necessary in order to protect the ladle flange and to prevent the building up of steel and slag on the ladle brim, which would jeopardize a satisfactory seal between the roofs and the ladle furnace, Ledoe 40/64 8 DANIEL! SERVICE Training Center The spout can either be attached by a hydraulically-operated device or placed on and removed from the ladle with the help of a crane. Hydraulic device is best! Deslagging Equipment The slag rake consists of water-cooled rake fastened to a telescopic beam. The beam performs a linear reciprocating movement. The pneumatic drive unit consists of two air motors (one to drive the telescopic beam linearly via a pull/push chain, and one for slewing the machine around a ball-bearing), ‘two pneumatic cylinders which tilt the telescopic beam and a pneumatic hoist for adjusting the elevation of the telescopic beam, The machine is controlled by hand and foot-operated pneumatic valves from a heat- insulated operator’s cabin situated over the telescopic beam. The drive unit, air pipes and hoses, and the bearings are also insulated against heat radiation. Connection terminal for compressed air and coolant water inlets and outlets are situated on the machine stand. Slag Making Demands on Slag Slag is always formed in steelmaking. The reason for this is that the steel always comes into contact with oxygen from the air. Alloy elements in the steel react with oxygen and form slag. Some slag comes from the refractory lining and consists of, for instance, MgO, SiOz and Al2O3, The “primary slag” that has been more or less drawn off after tapping into the ladle furnace has to be substituted by a new reducing slag, This is obtained by adding lime, which is also the main constituent in the oxidizing primary slag as well as in the subsequent reducing slag. In both cases it is thus a question of basic slags, the basicity of which should be 2-4 (CaO / Si02), depending on the extent of dephosphorization and desulphurization respectively to be done. In the ladle furnace slagmaking has a significant influence on the final result. Demands on the slag are: LF doe 41/64 Se DANIEL SERVICE Training Center a. The slag shall be able to take up impurities in the steel, e.g. sulphur and phosphours, which requires basic slag. b. The slag should cover the bath surface, thus preventing / reoxidation. ¢. The slag conserves energy and prevents heat loss through radiation. Strong heat radiation can damage the refractory lining, 4. The slag shall have a composition which is not aggressive to the refractory lining. Ledoe 42/64 © panu SERVICE Training Center Slagmaking in the Ladle Furnace Slag constituents In order to make the slag reducing, i.e. low in oxygen, agents such as ferrosilicon (FeSi), calcium silicon (CaSi), aluminium (Al), graphite (C), ete., may be added together with lime, but also regularly afterwards to prevent iron oxide being formed in the siag through oxidation by the air in the furnace atmosphere. It is thus important to make the oxygen that enters the slag inactive, otherwise it will counteract the sulphur removal. In iron oxide, oxygen is active, but by introducing such oxygen “lovers” as Si, Al and the like, it will be bound into such a strong relationship with these elements that it will be unable to affect the sulphur removal. ‘Slag formation in the ladle furnace is shown in figure y y A y G a 4 Yj 4 4 4 4 4 4 y 4 4 H iY = a Ledoe 43164 Se DANIEL! SERVICE Training Center Normally, just lime is added to the steel bath after alloying. Addition of calcium fluoride (fluorspar) increases the fluidity and calcium solution in the slag. Some silica comes from the refractory lining but most are deoxidation products formed after deoxidation during tapping from the primary furnace. Calcium oxide and silica are the main constituents of the slag. Typical basic slags are: LAF LF. black white CaO 50% 60% Si02 20% 25% FeO 15% 0,5% Black basic slag is formed during melt-down. The high content of iron oxide (FeO) makes it suitable for phosphorus refining, since FeO and CaO then cooperate to fix the phosphorus in the slag. White slag, with its low FeO content, is especially suitable for sulphur refining. Other main oxides formed in the slag are aluminium oxide (deoxidation product if aluminium is added) and magnesium oxide, coming from the lining in direct contact with the slag line, Addition of lime fluorspar A large amount of slag means that the CaS formed is diluted, so that the concentration is low. The sulphur refining reaction then proceeds to the right level. The same effect is obtained by changing slags! On the other hand, the addition of too much lime causes bad heat transfer to the steel bath. Lime and fluorspar should be added in connection with alloying, lime/fluorspar ratio approx. 10:1, addition approx. 0.5% of steel weight. If a too small amount of lime is added, the slag will contain an excess of silica, thus causing aggressive reaction with the lining, here assumed to be basic (magnesium oxide, calcium oxide and/or aluminium oxide.). After the addition of slag formers, maximum power shall generally be switched on, Le doe 44164 8 DANIELI SERVICE Training Center Temperature High temperature in itself really counteracts the desulphurization reaction (the equilibrium in the reaction becomes somewhat less favourable). Nevertheless, the total effect of high temperature is favourable, because it cteates good fluidity of the slag and the possibility of using high slag basicity, ‘The time for melting down is normally within 10 minutes, Stirring ‘The traditional method is based on the use of gas stirring and lime slag. The single slag practice is normally used. Ladle furnaces with deslagging equipment can of course ‘operate with more than one slag, The degree of desulphurization achieved with a single slag is at most 50-70%, Although gas stirring creates good conditions for desulphurization, the use of Ar bubbling for 5-10 minutes under vacuum increases the amount of desulphurization when using’ only lime slag. The degree of desulphurization with this method lies between 70-80%, and gives a final S content in the region of 0.005-0.007% depending on steel quality and the amount of slag. Carbon and silicon content in steel High contents of carbon and silicon make sulphur more “active” and more willing to react with lime. The carbon content therefore ought to be increased to its proper level as ‘soon as possible in connection with sulphur refining. LFdoe 45164 © paneeu service Training Center Stirring Stirring in general The advantages of stirring molten metal are mainly the same as those occurring in chemical processing, i.e. above all accelerated reactions and homogenization. The main purpose of stirring a melt is to speed up and facilitate: * Surface reactions, such as slag-ball reactions # Homogenization, for instance after alloy addition and during heating with respect to temperature distribution * Removal of inclusions after deoxidation In the case of slag refining it is important for the reaction kinetics that the slag is also stirred. The main purpose is to increase the active interfacial area between slag and molten metal, The slag is pulled by the flowing metal, and stirred if it is sufficiently fluid which can be influenced by high temperature (arc heating) and by adding fluxes, An efficient way of stirring the slag is to use gas blowing or bubbling. There is a need to homogenize the melt after the addition of alloys, during heating, etc. ‘The way to obtain rapid and efficient homogenization is to create powerful turbulence in the melt. Deoxidation, that is the removal of oxygen in the form of non-metallic inclusions, is speeded up and enhanced by stirring the melt. The kinetics of deoxidation comprise formation, growth and separation of the inclusions. Stirring speeds up the melting of the deoxidation reagent after addition and accordingly facilitates the formation and growth of inclusions. Most often the most critical step with respect to deoxidation rate is the separation of inclusions. If performed correctly without causing reoxidation of the melt, stirring improves and accelerates removal of the inclusions into the slag and refractory lining. Stirring is without doubt the most important tool in ladle metallurgy. It is a question of supplying the system with energy, which is transformed into motion of the steel and slag. This can be done with the aid of gas, induction or mechanical methods. LF.doc © 46164 e DANIEL SERVICE Training Center Stirring methods Successful ladle metallurgy is based on good stirring of the steel. Various methods and means are used to stir the steel in the ladle. A. Induction stirring, by means of: a. straight stirrer ». circular stirrer B. Gas stirring, argon or nitrogen, by means of: a. porous plug b. tuyeres c. immersion lance C. Mechanical stirring, by means of: a. “propellers” b. “shaking ladle” Ladle Furnace metallurgy is normally based on gas stirring, although induction stirrers sometimes are used. Mechanical stirring will not be dealt with in detail here, because of practical difficulties in ladle metallurgy. Other types of stirring methods not discussed in this chapter are: D. Circulation and pulsation mixing as practiced in DH, RH and PM equipment. E. Other types - at tapping from, for instance, primary furnace ladle - tank, stream degassing - chemical reactions, CO boil + thermal convection LRdee 47164 Se DANIELI SERVICE Training Center Induction stirring Stiming of a steel melt by the induction method is effected by a travelling electromagnetic field which penetrates the ladle wall into the steel. The stirring operates independently of the force of gravity. The direction of the stirring is reversible and can be regulated continuously from 0 to 100%. No special arrangements have to be made with regard to the reffactory lining. However, special ladles with non magnetic “windows” have to be used, which increases the investment costs. Also the cost of the installation is high. Professor J. Szekely has studied the stirring of steel melts by induction and gas from a hydrodynamic point of view. Figure 1 is taken from his work and demonstrates the typical flow pattem in a steel ladle stirred by induction. 4a ae 4 t+t 4a a 102) ' ha , ’ fh 4a Figure 1 Ltdoe 48/64 e DANIEL! SERVICE Training Center ‘The figure shows that the velocities of the stee! at the top and at the bottom of the steel bulk are approximately equal, and high (in the order of 07-1.0 mvs) giving a thorough “work through” of the melt. This stirring pattem is achieved with a comparatively calm stee] surface without splashing or bubbling, and thus giving very good conditions for the electric arcs to work when heating is taking place, Physically, induction stirring is characterized by: a. Thorough work through of the melt b. Calm surface ©, Close control of stirring power throughout the range 4, Direction of sticring reversible €. No change in refractory practice £. Special ladles needed Which gives the following benefits/drawbacks in the ladle metallurgy applications: 1, Homogenization of the melt, giving close temperature and analysis distribution, 2. Efficient transport of steel from bottom to top of the ladle, and viceversa, maintaining a “calm” steel surface which gives the best possible conditions for efficient are heating. Short “fat” arcs. Negligible carbon pick up. 3. Stirring can be done under cover of an unbroken slag layer, protecting the steel fiom influence of the atmosphere. 4, Effective removal of inclusions. 5, Reliable and safe stirring. No weak points in the lining. 6. Itis possible to hold steel in a ladle for long periods of time > 10 h (if necessary) 7. Low operation costs (no Ar, no plugs and no labour) 8. Promotes desulphurization, deslagging, etc. 9. High investment costs, LFdoe 49164 e DANIELI SERVICE Training Center Gas Stirring Gas stirring of steel is comparatively safe operation and is widely used. Compared to induction stirring the investment costs are lower since normal ladles can be used. Gas stirring has also mayor advantages when it comes to refining operations such as degassing, desulphurisation and dephosphorisation. The stirring force is generated by the rising gas bubbles and is influenced by the pressure and temperature conditions in the steel. ‘The gas can be fed into the melt via one or more porous plugs in the bottom of the ladle, or by alance, ‘The main purposes of gas bubbling into a melt are, as mentioned earlier: Homogenization of temperature and composition Removal of inclusions Promote slag-metal reactions Promote slag-atmosphere reactions Poe 50/64 Se DANIEL! SERVICE Training Center Comparison between induction and gas stirring With respect to heating there is a clear disadvantage with gas stirring. + The heat transfer from ares to bath is more inefficient + The stirring power from the gas tends to upset the electrode regulation due to the eruptive bath surface, This in turn causes carbon pick-up from the electrodes. Contributing reasons to the disadvantage of gas stirring in combination with arc heating may be mechanical complications, especially in the case where heating is done under reduced pressure. Disregarding the constellation stitring-heating, each stirring method has its merits ahead. of the other. Induction stirring may be combined with Ar stirring for special purposes: - High degree of desulphurization with lime slag is wanted - Assisting H removal when working with killed steels + Toreach very low C content when vacuum-decarburizing with oxygen ‘The combined use of induction and Ar stirring improves the operating conditions for the porous plug because the Ar is only used when necessary, which normally means 5-15 min/heat. This decreases the wear of the plug and thanks to the induction stirring there is no risk of freezing of the plug when not used, (Induction stirring will keep the bottom free from skulls). The plug lasts longer and Ar consumption is kept to a minimum. Stirring power from gas will only upset the electrode regulation if kept on high mode for sometime. Carbon pick-up will be minimal, Records must always be kept of porous plug stirring time. LFdoe 51/64 eS DANIELI SERVICE Training Center Induction Stirring in the Ladle Furnace Process In general the Secondary Steelmaking facilities have a lay-out which includes four “stations”, each with a special task: = Inspection of the ladle into the car, sometimes identical with the deslagging station Heating station Vacuum station Output station. Preparation for casting, Heating and vacuum treatments are primary unitary operations, see figure 2. They include in their tum several sub-unitary operations. These are: + Slag formation = Desulphurization ~ Deoxidation = Alloying - Degassing = Decarburization HEATING Slag formation Deoxidation Desulphurisation Alloying Temp. adjustment STIRRING VAC TREAT. Degassing Desulphurisation Alloying Decarburisation Figure 2 According to figure 1, induction stirring in the Ladle Furnace process is supplied during all unitary operations. LP doe 52/64 8 DANIEL! SERVICE Training Center General description of the Ladle Furnace induction stirring equipment The first twenty or so ladle fumace were delivered with cylindrical stirrers Today, the straight stirrer is standard. The reason for this is that this type of stirrer gives a better metallurgical result in spite of the fact that its mechanical stirring power is considerably less than that of the cylindrical stirrer. It is evident that the location in the melt of the applied force is more important than the power density. This description refers to the first figure in this chapter. The thyristor convertor feed low-frequency power to the stirrer. It contains, besides the thyristors, among other things an incoming isolator, a load circuit breaker and fault-indicating relays for which blocks the restarting of the convertor after fault tripping. The stirrer can be in operation with full power throughout the processing time. The stirrer equipment is operated from the furnace control room (and, where applicable, with a set of supplementary controls for ON/OFF, stirring direction and current at the deslagging station). The stirring current is adjusted to the desired strength by the control rotary switch by potentiometers, With a set of conveniently-located stop push-buttons it is possible to trip the stirrer (and the furnace breaker) should the circumstances so require. ‘The induction stirrer coil is mounted on (the tilting cradle of) the ladle car. It is supplied with low-frequency power and coolant water through a cable drag chain, so that the stirrer can also be in operation when the ladle is being moved from one processing station to another (and while the ladle is tilted during deslagging). The stirrer is cooled with distilled water (see separate instruction) which is circulated by pumps through a closed system containing a heat exchanger. The stirrer coolant water pump must be started as soon a8 a hot ladle has been brought into position in the ladle car. ‘The temperature of the coolant water can be checked on the monitoring and alarm unit in the control cubicle, A red light will be lit when the coolant water in the stirrer reaches 70° C (158° F). ‘When a push-button is pressed, the temperature in the corresponding cooling circuit will be indicated on the measuring instrument (which is common to all the measuring points), During normal operation the average temperature of the outgoing coolant water from the stirrer will be about 40-50° C, Leos 53/64 Se DANIEL SERVICE Training Center Operation of induction stirring Stirring can be controlled in two ways: - The power density from 0 to 130 Wim3 - The direction: Bither downwards along the stirrer wall or upwards along the stirrer wall The relationship between % stirring power and stirring current is shown in figure 3. % Stirring power 100 80 60 40 20 05 40 Stirring current kA Figure 3 Loe 54/64 e DANIEL! SERVICE Training Center How the stirrer should be operated depends on the prevailing circumstances, see also figure 4, INDUCTIVE’ STIRRING ‘epitaater ey ‘trection 1 Degassing 100% power Alloying: Slag ayer broken VOD Direction 1 Huang GD"G0% power Hanegtnalation Siegler unteken Deaton Desecaing Feel direction 1 wating Yi] 10 80K power Sania BAL Sect 2 er A Y LzzzzzzA p 14 olrection 2 Heating mA) power Hemogencisation Y OY trbrocen lg iyar 4 OF Hy UZZZZZZZLA Figure 4 Lrdoe 55/64 © panueu service Training Center INDUCTIVE STIRRING Character Direction 1 100% power Slag layer broken Direction 2 60-80% power Slag layer unbroken Direction 3 10-30% power Unbroken slag layer Direction 4 100% power Unbroken slag layer Use Degassing Alloying voD Heating Homogeneisation Deoxidation Deslagging ‘Waiting, Sampling Heating Homogeneisation Example PURPOSE ‘Working points of the stirrer DIRECTION POWER Destagging up “moderate” - maximum Desulphurization up/down ‘maximum Alloying up ‘maximum Vacuum treatment up maximum Carburization up maximum Removal of slag inclusions down max / mod Heating up - To increase the temperature up max / mod - To maintain the temperature up “moderate” Direction “up” gives a stronger force, enough to push the slag towards the opposite wall, leaving a “bare eye” of slag-ftee steel surface, where carburizers and other alloys can be added with satisfactory yield. LFaoe 56/64 eS DANIEL! SERVICE Training Center Even during vacuum treatment a bare eye may be desirable. In general the steel bath should be completely covered by slag in order to avoid excessive oxidation by the atmosphere. The combination of force and direction can obviously be varied infinitely. Local conditions and experience will indicate what is suitable, This possibility of variations is significant for the induction stirrer. ‘Most of these operations are discussed in separate chapters in this handbook. Here we only briefly consider desulphurization, homogenization with respect to alloying, and finally removal of non-metallic inclusions. Desulphurization Desulphurization in the Ladle Furnace can be carried out in many ways, providing good flexibility when optimising heat cycles. A. The traditional method is based on the use of powerful induction stirring and lime slag. The single method is normally used. Ladle furnaces with deslagging equipment can of course operate with more than one slag. The degree of desulphurization lies between 40-60%. B. Although induction stirring creates good conditions for desulphurization the combined use of induction stirring and Ar-bubbling for 5-10 minutes under vacuum increases the amount of desulphurization when using only lime slag. ‘The degree of desulphurization with this method lies between 70-80% and gives a final $ content in the region of 0.005-0.007% depending on steel quality and the amount of slag, C. Injection techniques are also used. The Ladle Fumace is extremely well suited for these techniques. ‘An example of the combined use of induction and Ar stirring using lime slag is shown in Table 1 below. Ar is used only when needed, i.e. when mixing the steel and the slag. The transport of steel from the bottom of the ladle to the reaction zone (surface) is handled by the induction stirring, (In the example the desulphurization is done under vacuum. This is not essential if there is no need for low H content). LFdee 57164 © panueu service Training Center Table 1 Results (40 t) Ss % % before Induction + Ar X= 0.036 X= 0.0095 3= 0.0127 8 = 0.0008 Aronly X= 0.039 X= 0.012 0.0091 3=0,0038 ‘The results refer to low-alloyed steel (C ~ 0.3%) and demonstrates that the combined use of induction and Ar stirring gives a more consistent desulphurization than Ar stirring alone. Homogenization, alloying The heat weights in steelmaking are varying from a few tons to several hundred tons. Regardless of the weight, the specified content of an element is sometimes in the order of only a few thousandths of one per cent (micro-alloyed steels). During the steelmaking it is therefore very important that the samples taken are representative of the whole melt, so that the right amount of alloys is added to obtain a correct final composition which is in accordance with the given specification. The last samples which represent the analysis certification (to be given to the client) are taken during the casting into moulds or in the continuous casting machine, Usually these samples are taken in the beginning, in the middle and at the end of casting. A homogeneous heat means identical composition of all three samples. Lede 98/64 Ss DANIELI SERVICE Training Center Efficient mixing is important in obtaining satisfactory results The concentration gradients which might occur if forceful mixing is not carried out are favoured by differences in density between the alloys and the steel bath, long dissolution time and also by thermal stratifications. The induction stirrer plays an important role here, too. Further, after fairly large additions it does not take more than a few minutes before a representative sample can be taken, see figure 5. pee... Homogeneisation rate * sD ete at Inductive stirring oo 200¢ a 1,00h a o 7 Toooa He 7 ‘SOA. 30 Time (min) Fig. 5 During the operations carried out while the steel is treated in the ladle fumace, non- metallic inclusions are formed in the melt. The “sinners” causing these impurities are deoxidizers, desulphurizers and alloys, ‘Whatever the reasons or origins are, the steel must be cleaned as well as possible from stich inclusions. In this respect, stirring is of the utmost importance. By agitating the steel, the included slag particles have a chance to make contact with the refractories or the slag blanket, to which they will stick. Another method of separating the inclusions frm the steel is to promote collisions between the particles, thus forming larger agglomerates which will float more rapidly up to the slag cover, where they will remain. The rate of agglomeration is strongly enhanced by stirring. Since the induction stirrer is switched on virtually all the time the ladle is resting in the car, the steel is constantly stirred. Lede 59/64 eS DANIEL! SERVICE Training Center Figure 6 shows the result of an investigation comparing Ar and induction stirring in respect of the total oxygen content of the steel vs. time. Figure 6 Induction stirring, when compared with gas stirring, gives: A. Faster oxygen removal B. Lower final oxygen C. Induction and Ar stirring in combination give slightly lower final oxygen than induction stirring only The cleanliness of the steel is closely related to the deoxidation practice. The techniques used vary, but one common factor is the role of induction stirring, For instance, induction stirring give a consistent and low Al loss independent of the stirring power, because of small losses to the slag, (Ar stirring gives losses higher than induction stirring and they are proportional to the stirring power) LP doe 60/64 8S DANIEL! SERVICE Training Center ALLOSS PPM/MIN 10} 30 700 750 STIRRING FORCE W/M3, Figure7 An example of an Al deoxidation technique used in a 100 t plant may be : Al is quickly plunged into the steel with a stopper rod crane. Maximum induction stirring is used. Up to 100 kg and more of Al can be added at one time. The Al is dissolved in about 1 minute. After 10-15 minutes the O value has stabilised. Ledes 61/64 Se DANIELI SERVICE Training Center EXAMPLE OF LADLE FURNACE OPERATIONS STEELMAKING 1. On arrival of Ladle at L/P, connect Ar hose line and start stirring 15/20 em eye, take temperature, and slag off if required, move carriage to roof position and lower roof, from local box on platform. 2. Power on tap (dependant on initial temperature (3 to 5 approx.). Increase stirring to 30 cm eye and add Ist 100 kg. CaO, Reduce stirring after addition made. 3. After 5-6 mins. take sample. Check slag condition for viscosity and colour. Take temperature if slag thick add CaF2 or other on 10-1 ratio. 4, On receipt of sample analysis. Calculate additions add alloys and 2nd 100 kg. CaO. Increase stirring whilst making addition. (N.B. Alloys will be calculated automatically from Level 2-3). 5. After 5-10 mins. (depending on amount of alloy addition) take sample and temperature, Check slag condition. 6. Adjust temperature whilst awaiting sample result to calculate correct temperature for ingot casting CCM, VD or VOD. 7. On receipt of analysis result, make trim additions (if necessary). This includes AL additions if Al killed steel or if AL over threshold limit and ladle going to ingots, CCM or VD/VOD. Take temperature, 8. If AL spec high and ladle going to CCM or ingots without VD/VOD make CaSi wire feeding for inclusion control. 9. If ladle to VD/VOD take AL, if AL spec, or Si if high Si, top of range to accomodate for drop in VD/VOD. If ladle to VD/VOD make sure free board adequate. 10. If temperature and analysis OK dispatch ladle to ingots, CCM, VD/VOD. LRdoe 6264 © panne service Training Center EXAMPLE OF LADLE FURNACE OPERATIONS, PULPIT CONTROL 1. Pre-requisites to starting make sure power available all systems operations (no alarms) spare electrodes ready in station. 2, When the roof is in the down position the process can be started, Close breaker and enables (A) power factor control and press auto button on electrode master control panel (electrodes will go down and strike an arc), 3, Tap setting should be set at tap (according temperature of metal) either automatic or ‘manual (A) or (manual) if on manual tap changer can be raised or lowered with the following buttons < up or > down 4, Gas stirring can be raised or lowered using the same type of buttons as in the previous paragraph. However this is better done initially from the local box to give the operator the chance to see the result: 15-20 em eye normal / 30 em making additions. 5. Induction stirring. This is operated with the same type of buttons as the gas, however the slag bulk will move away from the ladle wall and create a bare eye from the direction of the stirrer current eg. 6. Sampling / Temperature - Automatic The sampler or thermocouple is placed on the automatic pole, and the sample button is pressed on the control panel. The device will swing out on the piston, the roof door will open and the sampler on thermocouple will be inserted into the metal. After a preset time it will withdraw and the sample or thermocouple can be removed. This operation can also be done from the local box. 7. Sampling / Temperature - Manual The manual device is connected by cable to the recording system. First open viewing door and insert sample or thermocouple into metal. (If thermocouple on lancepole a red light will appear after a preset time a buzzer will sound and a yellow then green lamp will illuminate). (Withdraw lance from metal). The temperature will be recorded inside on the VDU and on a large lighted display (close door). 8. If taking sample the lance must be held under the slag metal interface approximately half way up the prube for approximately 6 seconds. Remove the lance take out sample and send to laboratory. Lrdoe 63/64 8 DANIEL! SERVICE Training Center 9. In automatic sampling it is not necessary to raise the electrodes although this may be done. In manual sampling / temperature taking this should be done as follows, 9A. Change electrode control from auto to hand A - Manual on master control. Raise electrodes on master control with this key T + then this > < to clamp in position. After sample/temperature has been taken press -> <~ (to unclamp) and the Aon master control, Electrodes will go down and strike arc, Inall cases of sample/temperature recording stirrer should be on low mode. 10. The position of all pushbuttons and switches are clearly indicated on the automation manual with instructions. LP doe 64164 DANIELI Training Center’ foe Fig. 165 Spray installation of the high speed castes Page 169

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