steelmaking research overview october 29, 2012 · metsim 1510 1530 1550 1570 1590 1610 1630 0 10 20...
TRANSCRIPT
Steelmaking Research Overview
October 29, 2012
Multi-faceted
Approach to
Solving
Steelmaking
Problems
Scope of Proposed Work (Proposed Research Method)
Industry Needs (Problem formulation)
Multi-scale Modeling (model)
Lab Experiments (data)
Industrial Trials/Validation (process, product)
Optimization Studies (industry data/parameters)
Modeling tools for steel processes Thermodynamic
METSIM
CFD
0
20
40
60
80
100
1300 1350 1400 1450
Temperature (C)
Au
ste
nite
(%
)
15
17
19
21
23
Cr
in liq
uid
(%
)
Liquid (equilibrium)
Liquid (Scheil model)
Cr in liquid (equilibrium)
Cr in liquid (Scheil model)
FACTSAGE
Process simulator
Phase equilibrium
Solidification
Refining
Inclusion chemistry
FLUENT
Molten steel flow
Energy
Multi-phases
Inclusion flotation
Macro-kinetics
Mass balances
Process analysis
Process design
Experimental
Metal casting lab with 200 lb IF
Automated SEM/EDS ASPEX Analysis
Mechanical tests
Thermal simulator
Levitation melting
10 LB VIF
1. New Continuous Steelmaking Process
Modeling
METSIM
1510
1530
1550
1570
1590
1610
1630
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
time (minutes)
ste
el
tem
pera
ture
(ºC
)
2750
2780
2810
2840
2870
2900
2930
2960
2990
ste
el
tem
pera
ture
(ºF
)
proposed continuous steelmaking conventional batch operation
LMF refining
tundish
mold mold
tundish
EAF
3-step refining
EAF
tap &
transport
transport &
sitting on turret
Energy Savings:
- less time and less heating in EAF
- no tapping into colder ladle
- no transport
- no holding
Lab experiments Industrial measurements
CFD FLUENT
Process parameters
Process design
2. Cleanliness of cast steel
0
0.0002
0.0004
0.0006
0.0008
0.001
0.0012
0.0014
0.0016
0.0018
0.002
Furnace, before
deoxidants
Furnace, after
Al
Ladle, after Ca Final Casting
Fra
cti
on
of
Inclu
sio
ns
Others
CaS
MnO
CA
Al2O3
MnSiO3
MnS
oxides
oxides
oxides
oxides
sulfidessulfidessulfidessulfides
0
0.01
0.02
0.03
0.04
0.05
0 0.01 0.02 0.03 0.04 0.05 0.06
Incl
usi
on
s fo
rme
d, w
eig
ht
%
Ca additive, weight %
Al2O3
MnS
CaS
CACA6
CaO
C3A
CA2
CA
y = -14199x + 28.439
R2 = 0.9597
0
2
4
6
8
10
12
14
16
18
20
0.0006 0.0008 0.001 0.0012 0.0014 0.0016 0.0018
Fraction of Area Covered by Inclusions
Ch
arp
y I
mp
act
Test
Valu
es (
ft-l
bs)
Modeling CFD FLUENT FACTSAGE
SEM/EDX ASPEX
Industrial trials
Improved Properties
Lab/Industrial Experiments
CFD - flow
Thermo-kinetics
METSIM – process model
Industrial measurements and model verification
3. Vacuum Tank Degassing
4. CO2 sequestration using slag Experimental kinetics
METSIM
Process modeling
Process design
5. Energy efficiency of melting steel Industrial benchmarking
Industrial measurements
`
Modeling
Heat balances
Potential Topics/Areas of
Steelmaking Research • Recycling of materials
– evaluation / economic models / reclamation
• New raw material development
– Hi Mn DRI / Reduce C footprint / Post-combustion
• Energy / Environmental / Productivity
– Yield improvement / slag splashing
• Cleanliness / Quality Issues
– Steelmaking / Refining / Casting
• Process development – Melt→Refine→Alloy→Treat→Cast→Roll→Heat-treat→Test