process metallurgy research unit
TRANSCRIPT
Process Metallurgy Research Unit
Professor Timo Fabritius
Head of the Research Unit
Centre for Advanced Steels Research
University of Oulu
University of Oulu
Process Metallurgy Research Unit
21.2.20192
FACTS (2018):
Staff: approx. 27
2.5 Full professor, 2 docents, 7 post docs
Degrees: 6 M.Sc., 3 Ph.D.
14 research projects (6 EU funded)
26 international publications
3 Spin-off companies (2012-2014)
RESEARCH FOCUS AREAS (scientific results during last three years)I. Reducing agents and reduction metallurgy (3PhD, 10M.Sc., app. 20 publ.,)
II. Primary and secondary metallurgy (2PhD, 10M.Sc., app. 20 publ.,)
III. Recycling and sustainable metallurgical processes (1PhD, 6M.Sc., app. 15 publ.,)
IV. New measurement and treatment methods in metallurgy (2PhD, 3M.Sc., app. 20 publ.,)- Microwaves, laser-based methods, optical emission and Raman spectroscopy
www.oulu.fi/pyometen
University of Oulu
Scientific Impact and Funding
21.2.20193 www.oulu.fi/pyometen
The publication analysis
is made by SciVal based
on the Scopus and Web
of Science data.
The scientific impact of
the Research Unit has
improved considerably
from 2007 to 2016.
The number of referee
publications has
increased and the
quality of publications
improved
Total funding 1,55 M€
Internal Funding
23 %
EU-Regional Develop Fund
2 %
Business Finland
27 %Academy of
Finland
12 %
EU (H2020, RFCS, EIT-RM)
16 %
Industry17 %
Foundations3 %
Process Metallurgy Funding 2018
University of Oulu21.2.20194
Reductants and reduction metallurgy
Coke reactivity,
hot and cold
strength of coke
Reducibility,
swelling and
softening of iron
ore pellets
Electrical
properties of
chromite ore
pellets and coke
Inorganic part of
the metallurgical
coke
Desulfurization of
hot metal
Results in the past three years
Academic
3 Doctoral thesis
~ 10 Master’s thesis
15 scientific publications
Industry
Successful acid pellet
development projects
Continuous research co-
operation and development in
coal and coke research
www.oulu.fi/pyometen
University of Oulu
Primary and secondary metallurgy
21.2.20195
Computational and
physical modelling of
fluid flows (AOD,
BOF, ladles, CAS-OB)
Thermodynamic-
kinetic modelling
of unit processes
(AOD, CAS-OB)
Assessment and
prediction of
inclusion
characteristics
Effect of
microalloyed
elements on slab
scaling properties
Results in the past three years
Academic
2 Doctoral thesis
~ 10 Master’s thesis
15 scientific publications
Industry
Decreased AOD tap-to-tap time
by process modeling
Decreased scale formation in
specific ferritic and austenitic
steel grades
www.oulu.fi/pyometen
University of Oulu
Recycling and sustainable metallurgical processes
21.2.20196
Replacement of coke
with biomass in
chromite pellet
sintering
Replacement of coal in
metallurgical coke
production
Recycling of dusts, scales
and sludges in steel
production (cold-bonded
briquettes)
Evaluation of
environmental impacts of
biomass use in carbon
steel production
Results in the past three years
Academic
1 Doctoral thesis
~ 6 Master’s thesis
10 scientific publications
Industry
Increased material efficiency in
hot metal production
Limitations of biomass use in
selected metallurgical
processes
www.oulu.fi/pyometen
University of Oulu
New measurement and treatment methods in metallurgy
21.2.20197
Results in the past three years
Academic
2 Doctoral thesis
~ 3 new PhD students
15 scientific publications
Industry
Commercialized OES system
(ArcSpec) saves up to 5–10%
of energy in EAFs
Limitations of microwave
technology use in difficult by-
product treatment
Laser-based imaging
methods for analysis of
electric arc processes
(Sapotech Oy)
On-line optical emission
spectrometry (wavelengths
ranging from ultraviolet to
infrared) (Luxmet Oy)
Time-gated Raman
spectrometry for analysis
of high temperature and
fluorescent samples
(Timegate Instruments Oy)
Use of microwaves to
recycle and recover
valuable metals from
metallurgical waste
www.oulu.fi/pyometen
University of Oulu
Steel melting shop
21.2.2019 Matti Aula8
Inclusions in liquid steel
• Composition of steel
• Composition of slag
• Temperature
• Time from alloying etc.
Cooling and solidification
• Solubilities decrease
• Segregation
Major changes in
inclusions
Inclusions after
solidification, before hot
rolling
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University of Oulu
Inclusion research
21.2.20199
Research focus
‒ Assessment and prediction of inclusion characteristics during
- Steel melt shop processes
- Continuous casting
- Hot rolling
‒ Distribution of alloying elements between steel matrix and inclusions
Main research approaches
‒ Scanning Electron Microscopy
‒ 3D Laser Scanning Microscopy
‒ Electrolytic Extraction
‒ Computational Thermodynamics
- FactSage
‒ Data Treatment
- MATLAB
www.oulu.fi/pyometen
University of Oulu
Electrolytic Extraction + Scanning Electron Microscopy
21.2.201910
‒ Reveals the true size and shape of
inclusions
- Electrolytic dissolution of steel sample
- Dissolving of steel matrix
- Detaching inclusions intact
- Filtration
- Scanning electron microscopy analysis (FESEM-EDS)
- Semi-automatic run: Size, shape, composition…
TiN inclusion (~10 µm) on a film filter. CaAlMgO+CaS inclusion (~13 µm) on a film filter.
www.oulu.fi/pyometen
University of Oulu
Electrolytic extraction: Distribution of elements in steel
21.2.201911
As a result:
‒ Almost all alloying elements can
be determined
‒ An estimate of alloying practice
success
‒ Comparative method for OES-PDA
technique for simultaneous study
of steel matrix and inclusions
‒ Possible link to predict steels
mechanical properties
Steel 1 Alloying element w-%
Ni Mn Ti Nb Cr
Spark-OES
(conventional
method)
0,17 0,38 0,15 0,42 18 Total
Extraction +
Elemental analysis
(developed
method)
0,17 0,38 0,08 0,21 18 Matrix
- - 0,07 0,18 - Inclusions
Benefits over conventional steel analysis, an example:
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University of Oulu
Computational thermodynamics
21.2.201912
FactSage calculations
‒ Distribution of sulphur
between
- liquid inclusions,
- solid CaS, and
- molten metal
as a function of Ca content in low-
alloyed steel (1520°C, Oxygen 10
ppm, Sulphur 10 ppm)
www.oulu.fi/pyometen
University of Oulu
Computational thermodynamics
21.2.201913
FactSage calculations
‒ Amount of inclusion components
‒ Composition of liquid inclusions
as a function of oxygen content in low-
alloyed steel (1550°C & 1600°C)
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University of Oulu
Data treatment
21.2.201914
Phase identification with MATLAB
‒ Data imported from IncaFeature
N (Wt%) O (Wt%) Na (Wt%) Mg (Wt%) Al (Wt%) Si (Wt%) S (Wt%) Ca (Wt%) Ti (Wt%) Cr (Wt%) Mn (Wt%) Zr (Wt%) Nb (Wt%)
0 35.49009323 0.035315733 0.991749644 14.02784538 0.524329007 7.757545471 37.114151 0.47289896 0 0 0.492527187 0.346165955
University of Oulu
Data treatment
21.2.201915
Identifying oxide–sulfide stringers with
MATLAB
‒ Data imported from IncaFeature
inclusion analyses is assessed to
identify stringers formed during hot
rolling
‒ The following properties are presented
for each stringer: the number of
inclusions and length of stringer,
phase fractions and compositions, and
the composition of the unfragmented
inclusion before hot rolling.
Properties of an oxide–sulfide stringer. Total length 35 µm.
University of Oulu
Data treatment
21.2.201916
Inclusion evolution from mould to
product
‒ Samples were taken from mould (liquid
steel) and from the hot rolled product
‒ TiN and CaS to some extent formed
during solidification
‒ Amount of oxides decreased,
composition changed
Inclusion components before and after casting & hot rolling
OxidesOxides
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University of Oulu
Main partners
21.2.201917 www.oulu.fi/pyometen