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

2. Steelmaking Process Map - Iron

3. Steelmaking Process Map - Refining

4. Basic Oxygen Furnace – Raw Materials
Fluxes
Coolant
Fuel

5. 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!

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

7. 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

8. 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

9. 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

10. 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