Improving the Modeling of Slag and Steel Bath Chemistry in an Electric Arc Furnace Process Model
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THE electric arc furnace (EAF) process represents the second-most important process route for steelmaking worldwide. Significant advances have been made in improving process understanding and control and optimizing energy and resource efficiency; however, there still is potential for further optimization. For this purpose, process models have proven to be useful tools and offer insight into the process that currently cannot be obtained through measurements due to the extreme conditions present in the EAF. Temperature and composition of melt and slag in the EAF are determined through spot measurements, often including a significant delay between sampling and receipt of the analysis, and remain unknown for most of the process. A comprehensive EAF process model describing the thermochemistry of the process can offer additional information by giving continuous predictions for composition and temperature throughout the process. Detailed thermochemical calculations, however, are computationally demanding for complex systems such as the EAF process. Therefore, existing comprehensive EAF models include only limited systems of reactions and species. THOMAS HAY, ALEXANDER REIMANN, and THOMAS ECHTERHOF are with the Department of Industrial Furnaces and Heat Engineering, Rheinisch-Westfa«lische Technische Hochschule (RWTH) Aachen University, Kopernikusstr. 10, 52074 Aachen, Germany. Contact e-mail: [email protected] Manuscript submitted March 5, 2019. METALLURGICAL AND MATERIALS TRANSACTIONS B
The process models developed by Nyssen et al.,[1] Cameron,[2] and Hofer et al.[3,4] are not described in sufficient detail to allow the identification and evaluation of the thermochemical models implemented. Matson and Ramirez[5–7] consider FeO and dissolved carbon for chemical reactions omitting all further trace elements. Bekker et al.[8,9] included Fe, C, Si, and the oxides FeO and SiO2 in their model, while Modigell et al.[10,11] included Fe, C, Si, Mn, and O dissolved in the melt and studied their reactions with oxygen and oxides in the slag using commercial software to obtain the necessary thermochemical data. Morales et al.[12,13] employed the quasichemical model to calculate the Fe and C contents of the melt with a slag formed by SiO2, CaO, MgO, Al2O3, and FeO. MacRosty et al.[14,15] published a detailed EAF model calculating the Fe, Si, Mn, Al, and C contents of the bath using the regular solution model (RSM) to calculate oxide activities in the slag and the unified interaction parameter formalism (UIP) for the activities of trace elements in the melt. The model, however, has been criticized for omitting relevant aspects including certain heat transfer mechanisms, while at the same time being computationally demanding due to the complex equilibrium calculations implemented.[16,17] Logar et al.[18–21] developed their model based on some of the principles published by MacRosty et al. and Bekker et al. while addressing several of the perceived shortcomings of these models. Being a comprehensive and recent model published in detail,
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