A Kinetic Ladle Furnace Process Simulation Model: Effective Equilibrium Reaction Zone Model Using FactSage Macro Process
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INTRODUCTION
THE ladle furnace (LF) or ladle metallurgical furnace (LMF) is one of the key secondary steelmaking process units for clean steel production. The unit has very strong stirring capacity through the bottom gas injection and arcing capacity to increase melt temperature. Therefore, active chemical reaction between slag and liquid steel can be achieved, and alloying of different elements can be carried out. The temperature drop of liquid steel in secondary steelmaking process can be compensated by reheating in this unit too. Due to the strong chemical reaction between slag and liquid steel, de-sulfurization (de-S) of steel can be carried out in this process using basic slag with high de-S capacity, and modification of non-metallic inclusions is also carried out to minimize their harmful effect on nozzle clogging and final steel product quality. There have been several studies on the kinetic simulations of the LF process, in particular, using the combination of thermodynamic calculations with simplified fluid dynamic equations of liquid melt in the ladle. Three most important models in literature were developed by Robertson’s group,[1] Irons’ group,[2] and Kitamura’s group,[3] which will be reviewed below. Although inclusion chemistry and slag/metal composition changes were taken into account in the model, the effect of electrical heating which automatically calculates the temperature of melt and slag was not included in any of these models. Recently, the present authors have proposed the Effective Equilibrium Reaction Zone (EERZ) model[4]
MARIE-ALINE VAN ENDE, Research Associate, and IN-HO JUNG, Associate Professor, are with the Department of Mining and Materials Engineering, McGill University, 3610 University Street, Montreal, QC H3A 0C5, Canada. Contact e-mail: in-ho.jung@ mcgill.ca Manuscript submitted January 11, 2016. METALLURGICAL AND MATERIALS TRANSACTIONS B
to simulate high-temperature metallurgical processes fully taking into account the complex chemical reactions at various reaction interfaces in the process. In particular, this approach can utilize the full power of thermodynamic database for complex thermodynamic calculations. The model has already been demonstrated for the process simulations of the basic oxygen furnace (BOF) process,[5] the RH (Ruhrstahl Heraeus) vacuum degasser,[4] and continuous casting mold flux variations.[6] In particular, FactSage[7] database was used for the thermodynamic calculation and FactSage macro processing was utilized to develop such a kinetic model. In the present study, a kinetic ladle furnace model was developed based on the concept of the EERZ model with FactSage database and macro processing code. The kinetic model incorporates slag/liquid steel/inclusion reactions and electrical arcing by the electrodes. The accuracy of the model will be demonstrated with real plant data.
II.
PREVIOUS LF MODELS
A. Metsim Model by Peter et al.[1] In 2005, Peter et al.[1] developed a simple LF model to simulate the chemistry change of slag and metal in the LF process. They consid
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