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1、TheNeedfFastRefiningProcessDr.Eng.EloyMartinezServMetEngineeringPueblaMexicoAbstract:Duetonewfastercastingofsteelbothprocessproductrequirementsfthinslabcastingplantsaremedemingthanconventionalslabcasting.SIFCprocessisabl

2、etodeliverthecrectqualityfcastabilitywithinthelimitedtime.Bothtimecompositionrequirementsareeasilymetbythisprocess.Nitrogencontrolbeingakeyissueisalsofulfilledbythisprocess.Keywds:inclusionfmationcalciumaluminumslagactiv

3、itycastabilitynitrogen.1IntroductionBecauseoftheadventofthinslabcastingtheevermedemingsteelmarketthereisaneedfaccuratecontrollableliquidsteelrefiningsystemsfthinslabcastingplants.TheSIFCprocessoffersanumberofadvantagesov

4、erconventionalsystemslikeaccurateslagcontrolinclusionfmation.Inthenextsectionsadeionoftheprocessisgivenanumberofexamplesfromdifferentsteelplants.2RequirementsfFastLiquidSteelProcessingThebasicrequirementsffastliquidsteel

5、refiningcanbedividedin2:Processrequirementsproductrequirements.ThesecanbefurtherbrokendownintothefollowingProcessRequirementsTimeConstrainsCastabilityCleanlinessTemperatureAimLimitedStirring[N]ChemicalComp.AimProductrequ

6、irementscanbesummarizedintochemicalcompositionconstrainsinclusiontypepopulation.Consideringtheaboverequirementstheneedofaprocesswithaccuratecontroloftheaboveisgreatlyneeded.Chinanowhasthepotentialoflargesteelmakersthequa

7、litywithwhichcanachievethisgoalwilldependonthetoolsusedtothisaim.3FundamentalsofSIFCProcessInclusionFmation.TheSIFCprocessstartsfromthetappingofsteelmakingvessels.Everysteelmakingvesselgeneratesdifferenttypesamountsofinc

8、lusionsdependingonanumberoffacts(123).Togiveanexampleoftheaboveinfigure1theinclusionsCaOAl2O3ratioisshownasafunctionofoxygencontentattap.00.511.522.533.544.5020040060080010001200?O[ppm]CaOAl2O3inprimaryinclusionsFigure1.

9、TheCaOAl2O3ratioofinclusionsfoundaftertappingofsteelmakingvessels.Ascanbeseeninfigure1theCaOAl2O3ratiomayvaryaccdingtotheoxygenvalueamongotherfacts.Thehighertheoxygenvalueattapthemedifficultistoobtainanycalciumcontentini

10、nclusionattap.Themphologyofinclusionsalsochangesdependingonthesevariables.Thebasicreactionsconsideredinthisprocessaresimultaneousaluminumwelldependingonoperationalfactslikecastsectionsizecastingthismayholdtrue.Howeverthe

11、truevalueofCaconsumptionisrelatedtothe“transfmed”inclusionsbycalcium.Tocrobatetheaboveresultsofdifferentplantsareshowninfigure4.Figure4showstheCaAlratiofoundininclusionsasafunctionofthe%SbefeCaadditionfdifferentcastsecti

12、ons.020406080100120Ca[ppm]012345CaAl[ininclusions]NipponSteel0.0005%SMartnez0.005%STAMSA0.0023%SHiltyFarrell0.015%SLu0.01%SHiltyFarrell0.005%SCaAlratiofoundininclusionsafterCatreatmentFigure4.CaAlratiofoundininclusionsas

13、afunctionofbothCaScontent.Ascanbeseeninfigure4asthe%SdecreasestheCaAlratioincreasesfthesameCacontent.ThisofcourseisthetrueCafunctionasamodifierofAluminainclusionsinthecaseofAKsteels.6ProductCleanlinessOneofthemainfeature

14、softheSIFCprocessistheobtainedcleanlinessofcastproducts.InthisrespectServMetEngineeringhasasignificantexpertisesoftwarecontrolftheSIFCfanygivenvesselsizeproducts.Twoexamplesaregivenasshownbelow.Fa165tonBOFvesselatIscFlat

15、SteelProducts[nowMittalSteel]VerbijlparkwksSIFCprocesswasupdatedwithanewsoftwareinNov.2004.PreviousresultsfanumbergradesdemonstratedthatinfactwithSIFCahigherAluminumcontentisachievedwithoutanegativeeffectincleanlinessass

16、howninfigure5.Figure5showsthealuminumcontentjustaftertapthefinalcleanlinessintheproductwhetherthisproductwasacceptedrejected.0.511.522.533.5Inclusioncount[ASTMe45]00.010.020.030.040.050.06wt%AlaftertapAcceptedAC534Reject

17、edAC534AcceptedAC234AcceptedAC133InclusionCountasaFunctionofAluminumContentafterTapGradesAC534AC234AC133Figure5.Resultsofproductcleanlinessfa165tBOFwithSIFCProcessAnothermeextremeexampleisshowninfigure6wheremedetailinfma

18、tionisgiven.FthebasisofcomparisonaconventionalSIFCprocesseswherebothtestedtheircleanlinessresultsevaluatedusingaQuantimetinstrumenttoquantifyparticlesize%Area.Asshowninfigure6eventhoughtheSIFCprocessyieldsahigher%Alinthe

19、productthisdoesnotincreaseGlobularoxides%areaincreasethenumberofparticles.%AeaParticlenumberfSIFCConventionalProcess[330tBOF]00.020.040.060.080.10.120.0290.0370.0280.0240.0280.0290.0350.0350.0350.0380.0320.035wt%Al%Area0

20、510152025303540No.Particles[GlobularOxides]%areaConv.%AreaSIFCNo.Part.mm2Conv.No.Part.mm2SIFCFigure6.Resultsofproductcleanlinessfa335tBOFwithSIFCProcessconventionalprocessbloombilletcasting.7NitrogenControlNitrogeniswith

21、outquestiononeofthemostdifficultissuesfprocesscontrol.Mostunftunatelyithasgreatconsequencesfproductproperties.BytheuseoftheSIFCprocessispossibletocontrolnitrogenpickupduringsteelmaking.Besidescontroltappingtoavoidlargeni

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