Professional Documents
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L.J. Heaslip
Atomic
J.D. Dorricott Arrangement
Examples
SOLID LIQUID
z There are many categories or classes of steel ALLOYS DEOXIDIZERS RESIDUALS GASES
alloys: plain carbon steels, alloy steels, C (carbon) Si^ (silicon) S (sulfur) O (oxygen)
HSLA (high strength low alloy) steels, free- Mn (manganese) Al (aluminum) P (phosphorus) N (nitrogen)
V (vanadium) Ca* (calcium) Cu (copper) H (hydrogen)
machining steels, stainless steels, etc. Mo (molybdenum) Mg* (magnesium) Zn* (zinc)
Cr (chromium)
Ni (nickel)
z specific grades of steel often have stringent Ti (titanium)
chemical specifications Zr (zirconium)
B (boron)
Nb (niobium)
z The majority of steels manufactured contain * Very limited solubility in liquid steel
^ Silicon deoxidation is usually enhanced with manganese
more than 97% Fe by weight (i.e., contain
less than 3% total of other elements)
Role of the EAF in Steel
Temperature of Liquid Steel
Production
z Steel melting in an EAF allows multiple types of iron units
in many forms and qualities, such as; steel scraps z Pure liquid iron solidifies at approx. 2800 F
(bundled, shredded, turnings, etc.) DRI (pellets, and/or (1538 C). The addition of other ingredients
briquettes), pig iron and iron carbide: such as carbon reduces this temperature called
1. to be formed into a homogeneous metal mass (the
molten steel bath), and
the liquidus temperature (the temperature at
2. to be chemically refined (i.e. adjusted in chemistry
which the liquid steel begins to solidify).
from an often unknown or highly variable state to a
known, controlled, and desirable condition)
z The superheat of the liquid is the number of
z Subsequently, the steel can be further adjusted by
deoxidation and alloying to meet product chemical degrees by which the temperature of the molten
specifications and then cast into a semi-finished shape metal bath exceeds the liquidus temperature.
(billet, bloom or slab) suitable for further processing into
primary steel products (bars, coils, sheets, etc.)
Oxidation reactions are a very important fuel Steelmaking depends upon the control
(energy source) and thus oxygen usage can of the liquid steel environment
reduce the electrical energy consumption of the
EAF
The control of oxide inclusions or dirt in the steel
is essential for control of castability and in clean
steel production
z For all of the above reasons, oxygen is the The liquid steel bath reacts with each phase it
critical and controlling element in steelmaking contacts and the control of oxygen in each of
chemistry these phases is essential
2Cu2O
Free Energy of Formation (Kcal)
-75
2CO
2FeO
-125
2/3Cr2O3
2MnO
2NbO
-175 2VO
SiO2
2TiO
ZrO2
-225 2/3Al2O3
2CaO
many other solute residuals in steel -275
500 700 900 1100 1300 1500 1700
Temperature (Deg. C)
MELTING DENSITY
OXIDE POINT (OC) (g/cm3)
HIGHER
z the most reactive forms of oxygen are: iron ore ~ 30 wt% O
oxygen gas (02)
Reduction Direction
oxygen in slag as iron oxide (FeO)
Oxidation Direction
O @ tap 3.
oxygen dissolved in liquid steel (O) 1. Blast
POTENTIAL
depends on C
Deoxidation Furnace
OXYGEN
& Alloying Ironmaking
each of these forms of oxygen is necessary and
desired for steelmaking refining, but precise 4.
control and reduction of active oxygen in the Reoxidation
Final O Ladle O
LOWER
steel and its environment is necessary when depends on deox. level
final chemistry is being reached and when steel 2. Steelmaking (typically 1 to 50 ppm)
BOF or EAF
cleanliness and castability' are determined
Steelmaking Pig Iron & Scrap
Charge 1-5 ppm O
z Oxygen and oxygen/carbon injection are essential z O2 gas, O , and FeO react with elements in the
components of EAF steelmaking: charge additional heating, aiding slag
to provide chemical energy and thus reduce KWH/ton forming and slag foaming, and providing
oxygen for refining reactions.
to oxidize slag (forming FeO) and oxidize the metal, thus
providing oxygen to remove elements from the metal Oxidation refining includes: removal of Al, Si,
having an affinity for oxygen (Al, C, P, Si, etc.) Ti, Ca, and P from the metal into the basic
to rinse the steel of undesired gases (H and N) oxidized steelmaking slag.
For example, aluminum and silicon removal:
to form CO gas to foam the slag, and thereby better
protect the bath from undesirable gases, stabilize the Si + 2O (SiO2)
arc, and protect electrodes and refractories from wear. 2Al + 3O (Al2O3)
Energy Benefit of
Oxygen Injection The Carbon Boil
1200
PCO = 1 Atmosphere O2(g) 2O - Oxygen gas dissolves into the steel.
Temperature = 1600 Deg. C
C + O CO(g) - Then Carbon and Oxygen in the steel combine to
form CO gas which bubbles out of the steel.
800
- This helps foam the slag and remove Hydrogen and
Nitrogen which are carried out in the CO bubbles
400
z The carbon/oxygen relationship indicates that the
oxygen content of steel when the melt is ready for
0
0 0.05 0.1 0.15 0.2 0.25 0.3 tapping is generally determined by the carbon level ,
Carbon (Wt.%) but:
Oxygen can be even higher than the range z Cover the Bath insulate the steel bath to
expected from the C/O relationship because reduce heat loss
slag/metal/gas equilibrium is not obtained in the
FOAMY SLAG
Slag Foaming
Performance
Balanced
Crusty
Watery
Crusty Watery
Apparent Slag Viscosity
- saturated in
reducing slag (lower in FeO)
F
Sl
Contact Angles affect Castability (Nozzle Higher contact angles imply an increased potential for
Clogging Potential of Oxides in Liquid Steel) sticking of the oxide inclusion to refractory surfaces
Lime Alumina
Phase Diagram Reoxidation
Video:
Reoxidation of
Steel Droplets
and Steel Streams
Oxygen Pickup by a Comparison of Deoxidation and
Falling Steel Droplet Reoxidation Inclusions
OF THE SLAG
INCREASING
INCREASING
O2- - free oxygen ion
ELECTRON
BASICITY
POWER
DONOR
O1- - terminal oxygen ion =
O0 - bridging oxygen ion
First Topics:
z The type and relative quantities of the cations in the slag (Ca2+,
Ladle Slag &
Ladle Slag-Line
Si4+, Mg2+, etc) govern the relative proportions of the three
Refractory forms of oxygen anions in the slag
For Clean Steels z The amount of free O2- ions in slag is the fundamental
measure of slag basicity and is related to Optical Basicity
Basicity
Desulfurization of
Optical Basicity Liquid Steel by Slag
z DEFINITION >>> z Sulfur is most effectively refined and removed from
steel under basic reducing slag
Electron Donor Power of the Slag
= z The reaction is: [S] + ( O2- ) ( S2- ) + [O]
Electron Donor Power of CaO
z for each unit of sulfur removed by basic slag, one
z CALCULATION >>> unit of oxygen enters the steel
for the reaction to go to low sulfur levels it is
Optical basicity values for the many oxides that are necessary to (1) provide sufficient basic reducing
found in slag can be found in a table and then a slag, to (2) stir the slag and the metal, and also to
tedious but simple calculation is performed: (3) maintain low dissolved oxygen levels in the steel
by good deoxidation
x1n11+x2n22+x3n33+..
Where:
Sulfur Removal
Equilibrium Slag/Metal Sulfur Partition
z The equilibrium partitioning of sulfur between the
slag and the liquid steel is governed by the sulfur
capacity of the slag CS, the chemical activity of
dissolved oxygen in the steel aO, and the absolute
temperature T (K).
(S) 770
[S] = log CS - log aO + 1.3 - T
log
(S) is the sulfur content or activity in the slag
[S] is the sulfur content or activity in the metal
z The sulfur capacity of the slag CS is determined z Ladle slags should be saturated in CaO to
by the slag chemistry. Optical basicity of provide the desired conditions for clean steel
slags has shown good correlation with CS. A production.
useful equation to determine CS using optical z Ladle slags should also be saturated in MgO
basicity () is as follows: to reduce the erosion of the ladle slag-line
refractories.
22690 54640.
Log CS = + 43.6. - 25.2 z Ladle slags should have a balanced fluidity
T
not-crusty and not-watery. Crusty slags will
is the optical basicity of the slag not absorb inclusions or sulfur and watery slags
attack refractory and can become emulsified in
T is the absolute temperature (K)
the liquid steel.
N pick-up is N pick-up is
enhanced by arcing hindered by foamy
After Greenberg and
McLean on a flat bath slag
This presentation will concentrate on the A ladle of water was used to simulate a ladle
understanding of ladle stirring by inert gas filled with liquid steel
bubbling
Typical Height/Diameter Ratio of a ladle
A non-isothermal physical modeling is ~1.1 to 1
approach has been developed that allows
observation & characterization of ladle mixing at 1:1 scale = 13 MT ladle
by gas bubbling at 1:2 scale = 105 MT ladle
Influence of thermal effects on stirring at 1:3 scale = 360 MT ladle
performance is investigated
Appearance of Isothermal
Water Model Design Bubbling with One Stir Plug
Side
Views
Up to
4 de
g.
Top
View
Bubble pile-up occurs at the leading end The bubble column rises
of the bubble column nearly vertically, but
Liquid inertia retards rise of leading with occasional swaying
bubbles toward wall and back
Following bubbles move quickly into the The top eye of the
wake of leading bubbles bubble column washes
Expected relationship: tm Q 1/3 the nearest ladle wall
Mixing time is inversely proportional A general overall
to the cubed root of the gas flow rate circulating flow pattern is observed.
1.7
front forming a downward plug flow -4.3 -4.1 -3.9 -3.7 -3.5 -3.3 -3.1 -2.9 -2.7
Critical Stir Plug Gas Flow Rates for Ladle with Two or More Stir Plugs
Different Ladle Sizes Non-Isothermal Stirring Flow Pattern
Stirring with Single Plug vs. Rod in Ladle Model These very high
Ladle Capacity
Critical Gas Flow (SCFM) gas flow rates
2.5 (metric T)
Log of Mixing Time - log(s)
Isothermal
1.1min @ 105 10.5 14.1 slag line
50 l/min
150 14.1 19.0 turbulence and
1.7
-4.3 -4.1 -3.9 -3.7 -3.5 -3.3 -3.1 -2.9 -2.7 210 18.3 24.7 opening of the
Log of Stir Gas Flow - log(cubic m/s) 280 23.2 31.4 slag cover.
360 28.9 39.0
To prevent excessive slag accumulation in the The dumping of steel from empty ladles after
tundish and to maintain cast steel quality, continuous casting is an expensive yield loss that can
easily cost a steel plant more than $1Million annually.
the ideal moment of ladle shut-off is the instant
when the proportion of slag/steel in the flow Thus, it is highly advantageous to retard the
entrainment of slag in the steel flow from the ladle
exceeds acceptable limits.
until all or very nearly all of the liquid metal is gone
However, even when flow is stopped at Two phenomena must be retarded or delayed:
the ideal moment, a significant quantity of
liquid steel can remain in the ladle due to formation of the draining vortex
vortexing and surface collapse collapse of the liquid metal bath surface.
The residual quantity of steel in ladles is often in Both computational analysis (CFD) and
the range of 1 to 5 tons or more, depending on water modeling have been used to
ladle size and casting rate. understand ladle draining phenomena.
100mm
150mm 100mm
There is a natural volumetric reduction
of 33% at 150mm metal depth
remaining, due to the increase of
refractory thickness in the ladle bottom
150mm m
0 0m
Depth 1
om
ott + 33% Flat Ladle Bottom
te dB
Til
tom
(microns)
Bot
Flat
Tilted Ladle Bottom
5
to TP Water Modeling & CFD (Computational Fluid
5
to Dynamics) Modeling have both been used with
2.5
3.0 M good correlations being found.
5 TP
<2.
Ladle Draining has 3 final stages:
1.5
Early vortex Full Vortex Surface Collapse
The steel depth in the ladle when these stages
0.0 occur is dependant on the draining (casting)
1.5 2.0 2.5 3.0 3.5
rate and the ladle bottom design
Ladle Bottom Diameter (m)
Summary (Contd) Summary (Contd)
When the full vortex develops before the slag
surface collapses (slag flush), there is still A tilted ladle bottom adversely affects the flow
residual liquid steel in the ladle. pattern of the draining flow by enhancing
surface velocity above the outlet
This residual in a flat bottom ladle can range from
1 to 3 tons at low draining rates (~2.5 TPM) Thus a tilted ladle bottom displays greater
increasing to as much as 5 to 6 tons at high inclusion contamination of the draining liquid
draining rates (5 to 7.5 TPM) in large ladles. steel as compared to a flat ladle bottom at
equivalent metal depth
The early vortex can entrains inclusions into
A tilted ladle bottom is less beneficial than
the steel resulting in a degradation of steel anticipated by the volume of steel removed.
quality entering the tundish before large
quantities of slag are entrained and before
the ladle is closed
Porous
Impact Area
Plug Area
Drainage
Channel Outlet
Area
3.0
Full Vortex is expected to be observed when the steel level
2.5 reaches a height of around 85mm over the outlet.
Early Vortex
Average
1.75T
1.5
Full Vortex
Medium elevation
7000 1800
Density of Outflow (kg/m3)
Prediction
6900 1200
= ~600 kg
at shut-off
6850 900
6800 600
6700 0
Time
4000
-flat upper terrace,
3500 Pred.
Approx. 0.75T 3000
Current Bottom-CFD
of steel can be 2500 -intermediate terrace, part of
saved from 2000 the mini-ELBY piece
each ladle 1500
1000
Pred.
-CFD
500 ELBY
0
2 2.5 3 3.5 4 4.5 5 5.5
La dle Em ptying Through-Put in T/m in
-lower channel for
vortex prevention and
15,000 Heats/Year * 0.75T = 11250 Tons/year
surface collapse
11250 Tons * US$125/Ton = approx. US$1.4 M/Year delay.
OR ~55 free ladles (almost 2 days production)
CFD Modeling CFD Modeling
Predicted Results Baseline vs Mini ELBY
ELBY vs Mini-ELBY
1.4 Baseline vs Mini-ELBY
3 Intermittent
Early Vortex
1.2 Baseline
0.9T Vortex
ELBY
Steel residual weight in Ton
2.5
0.2 Mini-ELBY
0
0 20 40 60 80 100 120
0
Steel level residual over outlet in mm
0 20 40 60 80 100 120
Steel level residual over outlet in mm
Stable Vortex:
Mini ELBY installed,
Increase of yield with the ELBY by (1.4-0.6=) 0.8T preheated, and ready for
service
Surface Collapse:
Increase of yield with the ELBY by (0.8-0.5=) 0.3T
The New Mini ELBY design concepts can reduce the
average steel residual in each ladle by 40% or more
z Terminology z Principle
R.A.D.A.R.: Rapid Monitoring the vibra-acoustic emission of
Analysis liquid steel flow from ladle to tundish yields
Detection signals directly related to:
And steel flow rate
Response
changes in flow behaviour which precede
the onset of slag entrainment, and slag
carryover, including vortexing
R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System
z General Equipment Schematic z Mittal Inland Inc. No.1 Slab Caster
1 Sensor
2 Sensor Signal
3 Preamplifier Module
4 Analysis Unit
5 Digital Data
6 Logic Unit
7 Status Signals
8 Operator Panel
9 Auto Valve Closure
10 Ladle Weight / Level Signal
11 Tundish Level Signal
12 Ladle Gate Valve Position
R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System
z Sensor Location z Sensor Detail
R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System
R.A.D.A.R. R.A.D.A.R.
Ladle Slag Detection System Ladle Slag Detection System
Vibra-acoustic vs Electromagnetic
100%
z
90%
ELECTROMAGNETIC SYSTEM
ALARMED FIRST
80% 13.3% of time
60%
30%
20%
0%
-20 -15 -10 -5 0 5 10 15 20
Time (seconds)
Cumulative alarm times of RADAR and
Electromagnetic systems compared to visual slag SLAG DETECTOR COMPARISON
(119 heats) Detection Capability
10
100%
9
90% Steel Residual in
Only vibra-
8 Ladle
acoustic can
Collapse
40%
Surface
Early Vortex
Full Vortex
30% 3
0 seconds = visual slag
20% 2
10%
1
0%
-20 -15 -10 -5 0 5 10 15 20
0
Time (seconds) 0 50 100 150 200 250
Steel head over outlet in mm
Summary Summary
A ladle bottom design for enhanced yield An automated ladle gate closure system has
(ELBY) has been developed been developed
This design incorporates a terraced shape with This design utilizes vibra-acoustic sensing
drainage channel technology
The ELBY design alters the draining flow pattern The system detects the onset of vortexing and
so as to control the steel flow path and reduce can be programmed for optimized sensing of the
sub-surface velocities to alleviate vortexing ideal moment for ladle gate closure
In this way, the early vortex can be avoided, while Both enhanced ladle bottom design (ELBY)
full vortex formation and surface collapse occurs and automated ladle closure (RADAR), can
at residual steel quantities 50% lower than with a
flat ladle bottom.
provide substantial yield and quality benefits
to the steelmaker.
Vital Functions
Tundish Act as a reservoir during ladle
Phenomena exchange
Distribution of flow between strands
Separation of non-metallic
inclusions
Control of casting speed
Tundish Design Development Tundish Design Development
How Must a Tundish Perform? How is a Tundish Optimized?
For Optimum performance the following must be A correctly designed tundish will
achieved Eliminate short-circuit flow and promote similar
Liquid steel must be uniformly distributed to each residence times for each strand on multiple outlet
strand casters
(thermally, chemically and dynamically) Control the propagation of turbulence from the ladle
Non-metallic inclusions and slag entrained within the stream inlet region down the tundish body
metal must be given time to separate by flotation Eliminate back mixing between the turbulent and
laminar flow regions of the tundish
Regions of stagnation resulting in temperature drop
and stratification must be eliminated Promote a quiescent surface condition and fluid flow
pattern for the flotation and elimination of inclusions
Short-Circuiting
Billet/Bloom
Caster
Slab Tundish
Caster
Tundish
1st
Generation
Performer Pad
Plug Plug
Flow Flow
t = 6 minutes t = 4 minutes
t = 50 s
Trap Zone
t = 115
s
t = 9 minutes t = 6.5 minutes
(a) Baseline - Current Pad (b) New Tundish - Performer Pad
Photo Series 12: Comparison of Baseline Current Pad and New Tundish Performer Pad, Drain Level = 15
t = 117 s
Photo Series 10: Comparison of Baseline - Current Pad and New Tundish Performer Pad, Drain Level = 15
Vortex
Killer
No Pad
Enhanced opportunities for inclusion flotation
- Reduced short-circuiting - Improved
residence time distribution = Cleaner Steel
Reduced turbulence in the impact zone - Less
slag entrainment = Improved Quality at Open End Ripple Pad
Ladle Exchange
Decreased skull size = $$$ in the Bank
VIDEO
The flow without Liquid steel is cooler in the tundish end and
impact pad is the far strand is 5C degrees (9F degrees)
swirling in nature. cooler than the inside strand.
This behavior leads
to a high potential
for slag entrainment,
thermal non-
uniformity between
strands, and short- Flo
Col wS
ore
d b tream
circuit paths for
yT l
inclusions to reach em ines
the strands. per
atu
re
IMPACT PAD FEATURES FLOW PATTERN-
OPEN END RIPPLE PAD
=0
bubble size. 80% .2
L
Efficiency
Removal Efficiency
B /L
=0
Inclusion removal is dominated by the .1
60%
probability of particle/bubble collision, thus
inclusion removal is maximized with small
Separation
bubbles. 40%
L L /
B L T = 480
L B /L
=0 =0
Collision probability B /L .4 qG = 0.0005
20% dp = 20m =0 .2
increases with decreasing .1
bubble size
0%
0 1 2 3 4 5 6 7 8 9 10
The TGD is
designed to
produce the
curtain of fine
bubbles
necessary to
maximize
inclusion
removal from
Diffuse Gas Curtain Before Diffuse Gas Curtain During
the tundish. Interaction with Particles Interaction with Particles
PARTICLE/BUBBLE Tundish Gas Diffusion
INTERACTION Model Results
Show Video 92m LLDPE particles in 1/3rd scale
100 water model, simulating 45m
inclusions in steel
90
30
45%
20
10
0
No TD Furniture Performer Pad Performer Pad
With TGD
Typical Current Gate Stack-up Advent Offset Gate Stack-up Typical Current Gate Stack-up Advent Offset Gate Stack-up
Offset
Offset GateTop
TopPlate
Plate Examples
Designs Introduces turbulent mixing at regulation area
entrance to reduce build-up and plugging at
Ripple Stopper with
this critical point
Round Step TWN
Oval Reduces incidence of sudden dropping in
Orifice stopper rod position
Orifice
Show Video
Mold Flow
Phenomena
NUMERICAL AND PHYSICAL NUMERICAL AND PHYSICAL
SIMULATION SIMULATION VIDEO
Show Video
Thin Slab
SEN A
Thin Slab
SEN B
Atmospheric Pressure
Pressure
Atmospheric Pressure
Z1 Z2
Z1 Z2 Z3
Constriction Zone
Control Zone
Z3
Control Zone
SEN Designs for Conventional Slab SEN vs.
Conventional Slab Casting Conical-Step Bore
Non-uniform flow in
Common Problems: the bore causes
non-uniform exit-jets
Clogging Build-ups in the
Bore & in the Ports Uniform flow in the
bore promotes
Wandering and
uniform exit-jets
Oscillation of the Exit-Jet
Flows
Reduced Clogging
In SES with Conical-Section Bore Reduced Clogging
Standard SES Advent
bore in SEN/SES SES bore
with
Conical Diffusing
Standard Advent Advent
SES SES SES Standard Bore Advent
SES port SES port
Bore Clogging Quarter Section Photos Conventional Slab SEN
Clogging starts much higher in the
bore and builds thickness downwardly
on both broad and narrow faces
(Current SEN)
Problem = Oscillating Unstable Port Flow Swirling
The symmetric
flow pattern
Thickest clogging at shown here is
bottom of bore and
Severe clogging at top of port bottom of port
not achieved in Actually
typical SEN/SES
Lowest Bumper
Clogging on the broad
port designs.
face starts below the
(Advent Conical Section SEN)
lowest bumper
Instant A Instant B
Little or no clogging
found on the narrow
face The asymmetric influence of the flow regulation mechanism
combined with the unstable nature of turbulent flows causes
Bumpers clearly Little top of port clogging
Slightly reduced unsteady swirling of the SES exit-jets
bottom clogging
evident
Conventional Slab
SEN COMPARISON
SEN
STD SES Conical-Step & TT Port Problem = Poor Utilization of Port Area
Conventional ports are never fully
utilized. (Typically ~ 60% of port
used). Port clogging can be
substantial.
Jets and gas bubbles are free to
wander causing mold flow instability.
Mould powder can be deposited
outside and inside the SEN by
reversed flows at top of the ports.
Furthermore, the jets are poorly
diffused generating high
impingement velocity on narrow
faces.
Conventional Slab SEN Terrace Multi-Port SEN
z THERMAL CONTROL
z LIQUID STEEL
Means Principally the Control of Bath
Is the Product of its Environment Temperature
z THE STEELMAKING ENVIRONMENT z PHYSICAL CONTROL
Consists of Slags, Refractories, and Gases Means Principally the Control of Fluid Flow and
Must be Controlled Thermally, Chemically, & Mixing Behavior
Physically z THESE CONTROLS ARE ALL LINKED
z CHEMICAL CONTROL Steel and Slag Stirring are Essential Components of
Is Strongly Affected by the Non-Metallic & Temperature and Chemical Control
Metalloid Elements Particularly Oxygen and Steel Refining Reactions, Slag/Metal Reactions, and
Carbon Re-Oxidation Phenomena are affected by the Flow