Overview of the steelmaking process pellets sinter limestone. Basic oxygen steelmaking bos, bop, bof, or osm, also known as linzdonawitzsteelmaking or the oxygen converter process is a method of primary steelmaking in which carbonrich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into lowcarbon steel. Principles and applications 344 pages 2000 ahindra ghosh 1420042319, 97814200423 the steelmaking industry and its customers have benefited enormously from the many significant technological advances of the last thirty years.
Iron and steel making processes are very complex in nature and we need. Currently, oxygen steelmaking accounts for 65% of worldwide crude steel production and is thus the predominant steelmaking process. Modeling related to secondary steel making request pdf. As the quantity of people taking part in a communication increases, the potential for errors in encoding and decoding increases.
Most previous advances have been based on empirical knowledge gained from experimentation with the process. In part 2 a kinetic model of the steelmaking process is developed based on the concept of effective equilibrium reaction zone and applied to the processing of a. The scrap metal is melted and refined using electrical energy. The process integration model is a good tool providing new insights into the material and energy system. Liquid steel is pour from converter to ladle through taphole. Ironmaking, the first step in making steel, involves the raw inputs of iron ore, coke, and lime being melted in a blast furnace. Influence of multiple factors on the alkali metal enrichment in blast furnaces by a thermodynamic model. Pig iron is divided into steel making pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. The steelmaking processes involve dynamic interactions among various phases slag, metal and gas along with chemical reactions, fluid flow. The complexity of the continuous casting process and the phenomena which govern it, illustrated in figs. The referred papers could illustrate the general and typical approaches in modeling the process and sub processes of steelmaking. Various chemical reactions are initiated, either in sequence or simultaneously, in order to arrive at specified chemical compositions and temperatures.
For example, for some grades of steel, such as rebar, the slag in the ladle plays a limited metallurgical role because of the fairly high p and s specifications of the steel. Modeling the liquid levels in the blast furnace hearth article in isij international 4110. Please note that s of certain materials are not owned by the steel plant museum of western new york. Steel making steel making process gerdau ameristeel utilizes the electric arc furnace continuous casting method in the production of structural steel products. Modeling of gas flows in steelmaking decarburization. Steel making is a process in which hot metal tapped from blast furnaces is refined into steel of the quality specified by customers. In a steelmaking shop, the output yield is considered as an important performance measure while producing a specific amount of steel. Modelling of kinetics of austenite formation in steels with different initial microstructures article pdf available in isij international 4110. The principle aim of the present study is to develop a. Oxygen is used to decarburize the molten steel and provide thermal energy.
It represents the operational efficiency of the steelmaking. Modeling of the steel manufacturing processes sang young lee department of health administration namseoul university, 21 maejuri, seongwaneup, cheonan, south korea. From the prediction of complex weather patterns to the design of swimsuits, modeling has, over the years, quietly but steadily become an essential part of almost every field and industry and steelmaking is. A kinetic and thermodynamic description of the steel making. During melting, oxidation of phosphorus, silicon, manganese, carbon, and other materials occurs, and a slag containing some of these oxidation products forms on top of the molten metal. It is the first step in making most of the products. Modeling of gas flows in steelmaking decarburization processes. As their customers become ever more quality conscious, however, steelmakers must continue their efforts to minimize harmful. In both the acid bessemer and basic bessemer or thomas processes molten pig iron is refined by blowing air through it in an eggshaped vessel, known as a converter, of 1525 tonnes capacity. However, with the increasing power of computer hardware and software, mathematical modeling is becoming an important tool to understand all.
Near end of tapping, dart is sucked into the taphole blocking the flow and limit slag carryover into the ladle. Dec 14, 2017 so, the present issue of steel research international may help production engineers in the steel plant to judge about the possible outcome of a simulation tool on one hand and may help the young researcher at the university to identify valuable topics for future simulationmodel developments on the other hand. These are basic oxygen steel making and electric arc furnace eaf steel making. Pig iron is divided into steelmaking pig iron, which is intended for further processing to steel by various refining processes, and foundry pig iron, from which cast iron is produced by remelting. Recycled steel scrap provides the raw material for the electric arc furnaces eaf. Special issue on modeling and simulation of steelmaking. Mathematical modeling of iron and steel making processes. The flow, mass transfer, and heat transfer in the reactors were. To analyze metallurgical thermomechanical problems to develop a new set of experimental property data based on inverse modeling to develop complicated thermomechanical models solid or semisolid variety of virtual experiments for process analysis and optimization. The liquid steel can then be cast or formed into a variety of solid shapes via the continuous casting process. Data based modeling approach to iron and steel making processes. Since scrap metal is used instead of molten iron, no coke making or iron making operations are associated with steel production using an eaf.
Steel processproduct modeling research overview october 29, 2012. Modeling of steelmaking processes dipak mazumdar, james. The growth of railroads during the 19th century in both europe and america put enormous pressure on the iron industry, which still struggled with inefficient production processes. Early processes of steel making were made during the classical era in science and technology in india, china, iran, and rome but the process of ancient steelmaking was lost in the west after the fall of the western roman empire in the 5th century ce. Bos is the most common and dominant primary steelmaking process used in the world today. Jun 21, 2016 these methods become popular for steel making into a heavy industry. Modeling of steelmaking processes books pics download new. Thermal expansion of particles in blast furnace, the effect of solid expansion due to temperature may. Steelmaking process an overview sciencedirect topics. Modeling of steelmaking process with effective machine learning techniques dipak lahaa, ye renb, p. Metal casting processes casting is one of the oldest manufacturing process.
Here the carryover slag has an advantage as it provides the necessary slag volume required for arcflare protection. Not all steel plants produce all of the products shown in this diagram. Steel rolling technology handbook 2nd revised edition. Discussing communication in terms of senderreceiver implies oneway communication.
Modeling of steelmaking process with effective machine learning techniques. Hayes this decidedly readable, informative book is perfectly suited for a range of audiences, from the novice graduate student not quite ready for sem to the advanced statistics instructor. Oct 28, 2014 the rest of the iron is used to make steel. Creating steel from lowgrade iron ore requires a long process of mining, crushing. Although there have been several studies on the applications of rf, ann, denfis and svm for modeling the inputoutput parameters of different complex processes, modeling using these techniques especially on prediction of output yield of the steelmaking process was not reported in the literature.
With basic oxygen steel making process liquid pigiron and scrap steel are collected. Steelmaking has played a crucial role in the development of ancient, medieval, and modern technological societies. Ann modeling of a steelmaking process springerlink. Tech student, department of metallurgical and materials engineering, iit madras, chennai, 600036, india 2asst. Addresses fundamental principles of physical and mathematical modeling in steelmaking processes.
However, few, if any, books offer the adequate coverage of modeling. This paper attempts to illustrate the benefits of using slag models based on the thermodynamics of steelmaking reactions and the multidimensional modeling of phase equilibria, in conjunction with massbalance calculations. In steelmaking, impurities such as nitrogen, silicon, phosphorus, sulfur and excess carbon most important impurity are removed from the sourced iron, and alloying elements such as manganese, nickel, chromium, carbon and vanadium are added to produce different grades of steel. Making mould cavity material is first liquefied by properly heating it in a suitable furnace. Pdf mathematical modeling of iron and steel making. Modeling continuous casting is used to solidify most of the 750 million tons of steel, 20 million tons of aluminum, and many tons of other alloys produced in the world every year. Data based modeling approach to iron and steel making processes sachin santosh1, ajay kumar shukla2 1m.
Cfd modeling and simulation in materials processing. Pdf in a steelmaking shop, the output yield is considered as an important performance measure while producing a specific amount of steel. Lecture 38 modeling of steelmaking processes contents. Hot metal from the blast furnace and steel scrap are the principal materials used in basic oxygen steel making bos modern furnaces, or converters will take a charge of up to 350 tonnes and convert it into steel in around 15 minutes. In order to validate the bof process model, the heats in 170. Therefore the industry is overwhelmingly dependent on modeling to quickly and costeffectively provide insight into analysis, design, optimization, and control of processing.
This is a batch process with a cycle time of about two to three hours. Steel is made by the bessemer, siemens open hearth, basic oxygen furnace, electric arc, electric highfrequency and crucible processes. Directly reduced iron directly reduced iron is a product of iron steel direct reduction from ores in the solid. Chapter 1 steelmaking, modeling,andmeasurements 1 1. Steelmaking is the process of producing steel from iron ore andor scrap. Cfd modeling and simulation in materials processing wiley. Steel making video course course outline introduction. Steel was still unproven as a structural metal and production of the product was slow and costly. It can serve as a benchmark for different steel making. Introduction to mediation, moderation, and conditional. Pdf dynamic multiphysics modeling for steel production. Continued development and installation of these processes will help relieve pressure on future prime scrap supplies and lessen domestic dependence on imported cold pig iron. In the steelmaking process that uses an electric arc furnace, the primary raw material is scrap metal.
The process models focus on part production employing electric arc furnace eaf steelmaking and sand casting with chemical binders, and. I am very much grateful to carl linder from sandvik material technology. The oxygen initiates a series of intensively exothermic heatreleasing reactions, including the oxidation of such impurities as carbon, silicon, phosphorus, and manganese. The purpose of this work is to develop a mathematical model to calculate the material balance. Modeling of steelmaking process with effective machine. This mode of deformation is found mostly on smooth bottoms of shallow parts and in hydroforming processes. Modeling of steelmaking processes books pics download. Molten steel thus produced is then processed into slabs, blooms and billets as semifinished products. This mode is typical the material flow from the flange towards the. Pdf modeling of steelmaking process with effective. Pdf a process model for eaf steelmaking semantic scholar. Such models are in the development stage, and some preliminary results.
The flow and chemical reaction in molten steel play an important role in these processes. Whereas mini mills operate successfully at 100,000 tonnes p. Further steps are made towards modeling of the whole process chain in the steel plant, rather than just the casting process. First, similar to openhearth steelmaking process, svr model can be used in modeling blast furnace process which plays a critical role in ferrous metallurgy industry and also in oxygen steelmaking converter which is currently producing aggregate approximately 80% of total world steel market. Thank you for all the information supplied for modeling. In sheet metal forming practice, we distinguish five basic modes of deformation. The experimental assistance form dan sandstrom from swerea mefos is greatly appreciated. Data based modeling approach of iron and steelmaking processes. It is the objective of management to maintain a high percentage of the yield. In this simulation you will play the role of plant metallurgist in charge of secondary steelmaking operations. Bim represents a new paradigm within aec, one that encourages integration of the roles of all stakeholders on a project.
Basic oxygen furnace bof converter in tapping position. Overview of the steelmaking process pellets sinter limestone coke iron ore coal scrap blast furnace ironmaking converter steelmaking ladle refining blast furnace steelmaking coalnatural gas plate hotrolled bars rods tube rounds rails slab billet bloom hotrolled and coldrolled strip coils structural shapes. Liquid steel temperature in ladle during steel making and casting. Pdf development and application of models for steelmaking and. Dart designed to float at interface between steel and slag. Of the three major steelmaking processesbasic oxygen, open hearth, and electric arcthe first two, with few exceptions, use liquid blastfurnace iron and scrap as raw material and the latter uses a solid charge of scrap and dri. Analyzes mechanistic, ai based, and macroscopic models, to provide a holistic view of steelmaking. With content designed to serve professionals and students, this book starts with an overview of steelmaking and develops into a focused description of underlying scientific fundamentals and applications. Steel scrap is metallic iron containing residuals, such as copper, tin, and chromium, that vary with its origin. Analyzes mechanistic, aibased, and macroscopic models, to provide a holistic view of steelmaking. Basic oxygen process bop, a steelmaking method in which pure oxygen is blown into a bath of molten blastfurnace iron and scrap. Salzgitter the process shown above is illustrative only and is not designed to show the steelmaking process in detail. Modeling of gas flows in steelmaking decarburization processes zhili song doctoral thesis stockholm 20 division of applied process metallurgy department of materials science and engineering school of industrial engineering and management royal institute of technology se100 44 stockholm sweden.
The cast steel can then be forged or rolled in successive steps to produce anyone of the many required shapes. In principle, steelmaking is a melting, purifying, and alloying process carried out at approximately 1,600 c 2,900 f in molten conditions. Pdf ann modeling of a steelmaking process researchgate. You will take charge of a ladle of molten steel from the basic oxygen furnace bof, and attempt to deliver it to the appropriate caster at the specified time, composition, temperature and inclusion content cleanness. The present study was performed considering the openhearth process of a steelmaking shop. In the present day, we have two popular methods used for making steel in commercial processes. It is very nicely written, very good pictures and excellent guideline for creating your own model industry.
Molten steel thus produced is then processed into slabs, blooms. Design of a physical model for fluid flow in steel melt. Introduction to mediation, moderation, and conditional process analysis a regressionbased approach andrew f. Scale modeling of steel making processes springerlink. Addresses fundamental principles of physical and mathematical modeling in steelmaking processes modeling of steelmaking processes. It has the potential to promote greater efficiency and harmony among players who, in the. This transition is usually accomplished by the steel being sprayed by water as it travels the length of the rollers. Professor, department of metallurgical and materials engineering, iit madras, chennai, 600036, india abstract. The steel is now in a semifinished solid state and can either be sent to customers or undergo finishing refinement processes. Thank you for all the discussions through emails and physical meetings. Iron ore processing for the blast furnace courtesy of the national steel pellet company the following describes operations at the national steel pellet company, an iron ore mining and processing facility located on the mesabi iron range of minnesota. The best subset regression analysis is applied to determine the most influencing variables influencing the output of the steelmaking process.
Modelling of kinetics of isothermal allotriomorphic and idiomorphic ferrite formation in medium carbon. Two processes, basic oxygen steelmaking bos and electric arc furnaces eaf, account for virtually all steel production. Jan 14, 2020 two processes, basic oxygen steelmaking bos and electric arc furnaces eaf, account for virtually all steel production. Tech student, department of metallurgical and materials engineering, iit madras, chennai. A primary steelmaking process refers to the actual process of taking the raw materials and. However, human communication often is a twoway process in which each party shares sending and receiving responsibilities.