EDSGN Kick Off Meeting – 2/27/2012 Steelmaking Basics and Project Overview R. Zellers

Steelmaking Process Map - Iron

Steelmaking Process Map - Refining

Basic Oxygen Furnace – Raw Materials Fluxes Coolant Fuel

BOF - Reactions Decarburization 2C + O2  2CO (reaction occurs in bath, CO to off gas) 2CO + O2  2CO2 (reaction occurs above bath, CO2 to off gas) Silicon Oxidation Si + O2  SiO2 (reaction occurs in bath, SiO2 to slag) Manganese Oxidation Mn + O2  MnO Aluminum Oxidation 4Al + 3O2  2Al2O3 + HEAT!

Chemistry of “Open” Steel Mn 0.1% Cr 0.01% Cb 0.00% Al 0.00%

BOF – Order of Reactions – Ellingham Diagram 2Fe + O2  FeO2 Cr: 1/2 C + O2  CO2 Mn: 1/3 Energy Si: All 2C + O2  CO2 4Cr + 3O2  2Cr2O3 Al: All 2Mn + O2  2MnO Si + O2  SiO2 Ca: All 2Ca + O2  2CaO 4Al + 3O2  2Al2O3 Temperature

Alloying – Why & Where? Aluminum – Deox, aluminum-nitride grain refining Carbon – Strengthener Calcium – Inclusion modification, castability Chrome – Hardening, corrosion resistance Columbium (Niobium) – Grain refining Manganese – Strengthener, heat treatment hardening BOF during tap – Good mixing, allows for “settling” Ladle met facility – Greater control

Alloy Calculation Example: LCAK Mn addition Aim: 0.2% Already in steel from BOF: 0.1% Needed from alloy: 0.1% Heat Size: 440,000 lb HC Mn: 78% Mn, 90% Recovery (note: “pure alloy” in project) Calculation: (0.1% Mn/steel) * (440,000 lb steel) = 440 lb Mn (440lb Mn) / (78% Mn/HC Mn * 90% Recovery) = 627 lb HC Mn

Project Part 1 – No Off Chemistries Separate advanced high strength steel (AHSS) from scrap autos Use mix of AHSS and low carbon aluminum-killed (LCAK) scrap to make LCAK heat Part 2 – Cost Savings Utilize AHSS scrap to make line pipe heat Calculate addition alloys needed