Title

IMPROVING EAF OPERATION BY APPLICATION OF THE REFINING SIMULATION AND FOAMING MASS BALANCE

IMPROVING EAF OPERATION BY APPLICATION OF THE REFINING SIMULATION AND FOAMING MASS BALANCE

Authorship

PRETORIUS, EUGENE; OLTMANN, HELMUT

PRETORIUS, EUGENE

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OLTMANN, HELMUT

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DOI

10.5151/2594-5300-3201

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Abstract

The paper discusses some of the principles involved in the application of the Refining Simulation and EAF Foamy Mass Balance programs to improve EAF operating practices and lower costs. Improved foaming slag conditions in terms of the choice of target slag, consistency and length of foaming are discussed. The back-calculation of scrap chemistry to better design flux recipes and for compilation of a historical database to enable predictive control of slag compositions, has enormous potential to improve the consistency of foaming in the EAF. The Refining Simulation shows the potential for changes to charge design and/or injection parameters that can improve the endpoint control (final %C in metal and %FeO in slag) to limit over-oxidation and yield losses. The relations between melt-in chemistry, injection parameters and extent of decoupling of reactions to control the end point, is demonstrated by the simulation. The effect of process changes should be quantified with the aid of a mass and energy balance to ensure a beneficial effect on the overall situation of production rate and site-specific cost. For a proper evaluation and optimization of the EAF process it is important to include the directly quantifiable, as well as the long-term consumption parameters like Fe-yield, refractory and electrode wear.

The paper discusses some of the principles involved in the application of the Refining Simulation and EAF Foamy Mass Balance programs to improve EAF operating practices and lower costs. Improved foaming slag conditions in terms of the choice of target slag, consistency and length of foaming are discussed. The back-calculation of scrap chemistry to better design flux recipes and for compilation of a historical database to enable predictive control of slag compositions, has enormous potential to improve the consistency of foaming in the EAF. The Refining Simulation shows the potential for changes to charge design and/or injection parameters that can improve the endpoint control (final %C in metal and %FeO in slag) to limit over-oxidation and yield losses. The relations between melt-in chemistry, injection parameters and extent of decoupling of reactions to control the end point, is demonstrated by the simulation. The effect of process changes should be quantified with the aid of a mass and energy balance to ensure a beneficial effect on the overall situation of production rate and site-specific cost. For a proper evaluation and optimization of the EAF process it is important to include the directly quantifiable, as well as the long-term consumption parameters like Fe-yield, refractory and electrode wear.

Keywords

EAF operation, foaming slag, refining, mass balance, refining simulation

EAF operation, foaming slag, refining, mass balance, refining simulation