General heat balance for oxygen steelmaking
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ORIGINAL PAPER
General heat balance for oxygen steelmaking N. Madhavan1
•
G.A. Brooks1 • M.A. Rhamdhani1 • B.K. Rout2 • A. Overbosch2
Received: 31 March 2020 / Revised: 6 May 2020 / Accepted: 20 May 2020 China Iron and Steel Research Institute Group 2020
Abstract Energy balances are a general fundamental approach for analyzing the heat requirements for metallurgical processes. The formulation of heat balance equations was involved by computing the various components of heat going in and coming out of the oxygen steelmaking furnace. The developed model was validated against the calculations of Healy and McBride. The overall heat losses that have not been analyzed in previous studies were quantified by back-calculating heat loss from 35 industrial data provided by Tata Steel. The results from the model infer that the heat losses range from 1.3% to 5.9% of the total heat input and it can be controlled by optimizing the silicon in hot metal, the amount of scrap added and the postcombustion ratio. The model prediction shows that sensible heat available from the hot metal accounts for around 66% of total heat input and the rest from the exothermic oxidation reactions. Out of 34% of the heat from exothermic reactions, between 20% and 25% of heat is evolved from the oxidation of carbon to carbon monoxide and carbon dioxide. This model can be applied to predict the heat balance of any top blown oxygen steelmaking technology but needs further validation for a range of oxygen steelmaking operations and conditions. Keywords Heat balance Static model Process control Optimization Basic oxygen steelmaking Heat loss List of symbols CpX Specific heat of X (kJ/(kg K)) HDiss_X Heat of dissolution of X (kJ/kg) HHR_X Heat of reaction of X (kJ/kg) HT Enthalpy at temperature T (kJ/kg) H298 Enthalpy at 298 K (kJ/kg) L Latent heat (kJ/kg) T Temperature (K) Tfg Flue gas temperature (K) THM Hot metal temperature (K) Tm Melting point of steel (K) Tslag Slag temperature (K) Tsteel Steel temperature (K) Wfg Mass of flue gas (kg) WHM Mass of hot metal (kg) Wscrap Mass of scrap (kg) Wslag Mass of slag (kg) Wsteel Mass of steel (kg) & N. Madhavan [email protected] 1
2
Department of Mechanical and Product Design Engineering, Swinburne University of Technology, Hawthorn 3122, VIC, Australia Tata Steel, Ijmuiden 1951 JZ, The Netherlands
w(C)HM w(C)steel w(Fe)HM w(Fe)scrap w(Fe)steel w(Mn)HM w(Mn)steel w(P)HM w(P)steel w(Si)HM w(Si)steel w(CaO) w(FeO) w(MgO) w(MnO) w(P2O5) w(SiO2) X
Carbon content of hot metal (%) Carbon content of steel (%) Fe content of hot metal (%) Fe content of scrap (%) Fe content of steel (%) Mn content of hot metal (%) Mn content of steel (%) P content of hot metal (%) P content of steel (%) Si content of hot metal (%) Si content of steel (%) CaO content in slag (%) FeO content in slag (%) MgO content in slag (%) MnO content in slag (%) P2O5 content in slag (%) SiO2 content in slag (%) Corresponding elements in hot metal or oxides in slag
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