A Novel Modeling Method of Slag Foaming in BOF
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e slag foaming is a complex dynamic process, which plays an important role during the BOF steelmaking process. The moderate level of slag foaming is beneficial to improve the kinetic conditions of chemical reactions,[1] smelting efficiency and energy utilization efficiency.[2] However, insufficient or excessive level of slag foaming might deteriorate the smelting effect, possibly causing severe accidents, such as splashing outside the furnace,[3,4] consequently resulting in human injuries and equipment damage. To control the slag foaming accurately, it is vital and necessary to conduct further studies on the BOF slag foaming. In the BOF smelting process, the slag foaming is mainly induced by the carbon-oxygen reaction between the slag and metal,[5] as presented in Eq. [1]. The BOF slag foaming is a very complex process with characteristics of high temperature, multiphase,[6] multi-factor effects[7–9] and dynamics,[10,11] which lead to significant difficulties in the on-site observation and the simulation experimentation at high temperature on slag foaming. To study the splashing behavior in BOF, it is common practice to simulate the interaction between the oxygen
RUIFANG WANG, BO ZHANG, CHENGJUN LIU, and MAOFA JIANG are with the Key Laboratory for Ecological Metallurgy of Multimetallic Ores (Ministry of Education), Northeastern University, Shenyang 110819, P.R. China and also with the School of Metallurgy, Northeastern University, Shenyang 110819, P.R. China. Contact e-mail: [email protected] Manuscript submitted October 10, 2019.
METALLURGICAL AND MATERIALS TRANSACTIONS B
lance jet and the metal in BOF through physical modeling,[12–15] in which the role of the slag phase was ignored. Furthermore, several researchers[16–18] attempted to explore the multiphase interaction of gas–slag–metal in the BOF through physical and numerical simulations. However, neither the slag foaming phenomenon nor the chemical reaction in BOF was considered in the above studies, for which the conditions deviated from the actual smelting conditions in BOF. Qiu and Zhu et al[1,19] successfully simulated the foaming phenomenon caused by chemical reaction, but failed to accomplish an accurate BOF process simulation. ðFeOÞ þ ½C ¼ ½Fe þ CO ðgÞ
½1
Therefore, based on the similarity principle, the BOF slag foaming process was simulated through physical modeling in this investigation. A physical model was developed with a prototype of a 200 t BOF in China. The chemical reaction of sodium carbonate powder dispersed in silicon oil with sulfuric acid solution [Eq. 2] was used to simulate the carbon-oxygen reaction on the slag–metal interface in BOF. Through this method, the slag foaming process was presented in the BOF, including generation—development—stability—decaying processes. In addition, the effects of slag viscosity and gas amount on the evolution of slag foaming was studied. Na2 CO3 ðsÞ þ H2 SO4 ðaqÞ ¼ Na2 SO4 ðaqÞ þ CO2 ðgÞ þ H2 O
½2 The geometric similarity, dynamic similarity and similarity of physical properties were considered in this e
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