Operations and Basic Processes in Steelmaking PDF
Preview Operations and Basic Processes in Steelmaking
Topics in Mining, Metallurgy and Materials Engineering Series Editor: Carlos P. Bergmann Luis Felipe Verdeja González Daniel Fernández González José Ignacio Verdeja González Operations and Basic Processes in Steelmaking Topics in Mining, Metallurgy and Materials Engineering SeriesEditor CarlosP.Bergmann,FederalUniversityofRioGrandedoSul,PortoAlegre, RioGrandedoSul,Brazil “Topics in Mining, Metallurgy and Materials Engineering” welcomes manuscripts in these three main focus areas: Extractive Metallurgy/Mineral Technology; Manufacturing Processes, and Materials Science and Technology. Manuscripts should present scientific solutions for technological problems. The three focus areas have a vertically lined multidisciplinarity, starting from mineral assets, their extractionandprocessing,theirtransformationintomaterialsusefulforthesociety, andtheirinteractionwiththeenvironment. Moreinformationaboutthisseriesathttp://www.springer.com/series/11054 · Luis Felipe Verdeja González · Daniel Fernández González José Ignacio Verdeja González Operations and Basic Processes in Steelmaking LuisFelipeVerdejaGonzález DanielFernándezGonzález EscueladeMinas,EnergíayMateriales EscueladeMinas,EnergíayMateriales UniversityofOviedo UniversityofOviedo Oviedo,Asturias,Spain Oviedo,Asturias,Spain JoséIgnacioVerdejaGonzález EscueladeMinas,EnergíayMateriales UniversityofOviedo Oviedo,Asturias,Spain ISSN2364-3293 ISSN2364-3307 (electronic) TopicsinMining,MetallurgyandMaterialsEngineering ISBN978-3-030-67999-6 ISBN978-3-030-68000-8 (eBook) https://doi.org/10.1007/978-3-030-68000-8 ©TheEditor(s)(ifapplicable)andTheAuthor(s),underexclusivelicensetoSpringerNature SwitzerlandAG2021 Thisworkissubjecttocopyright.AllrightsaresolelyandexclusivelylicensedbythePublisher,whether thewholeorpartofthematerialisconcerned,specificallytherightsoftranslation,reprinting,reuse ofillustrations,recitation,broadcasting,reproductiononmicrofilmsorinanyotherphysicalway,and transmissionorinformationstorageandretrieval,electronicadaptation,computersoftware,orbysimilar ordissimilarmethodologynowknownorhereafterdeveloped. Theuseofgeneraldescriptivenames,registerednames,trademarks,servicemarks,etc.inthispublication doesnotimply,evenintheabsenceofaspecificstatement,thatsuchnamesareexemptfromtherelevant protectivelawsandregulationsandthereforefreeforgeneraluse. Thepublisher,theauthorsandtheeditorsaresafetoassumethattheadviceandinformationinthisbook arebelievedtobetrueandaccurateatthedateofpublication.Neitherthepublishernortheauthorsor theeditorsgiveawarranty,expressedorimplied,withrespecttothematerialcontainedhereinorforany errorsoromissionsthatmayhavebeenmade.Thepublisherremainsneutralwithregardtojurisdictional claimsinpublishedmapsandinstitutionalaffiliations. ThisSpringerimprintispublishedbytheregisteredcompanySpringerNatureSwitzerlandAG Theregisteredcompanyaddressis:Gewerbestrasse11,6330Cham,Switzerland ThisbookisdedicatedtothememoryofJosé AntonioPero-SanzElorz(1934–2012), who foundedtheresearchgroupinironand steelmaking,metallurgyandmaterialsatthe UniversityofOviedo(Asturias,Spain)inthe middleoftheseventiesofthelastcentury. Severalbookshavebeenpublishedasaresult ofthislongperiodofresearchandteaching, including PhysicalMetallurgyofCastIrons (Springer,2018),StructuralMaterials: PropertiesandSelection(Springer,2019) andOperationsandBasicProcessesin Ironmaking (Springer,2020). Prologue Iron together with copper are the only elements of the Periodic Table related with the four Human Ages: Stone, Copper, Bronze, and Iron. According to the history, approximately1500yearsBC,itispossibletolocatethebeginningoftheIronAge intheHittitesKingdom,inthecenteroftheAnatolia’speninsula,formerTurkey. EvenwhentheartoftheironobtainingsinksitsrootsintheHumanhistory,the science and technology of the steel as material used in structural applications has onlyhadamarkeddevelopmentfromthesecondhalfofthenineteenthcentury,when thesteelproductionexceededmillionsoftonsinoneyear.Alongthesevenchapters ofthisbook,wedescribetheoperationsandindustrialprocessesassociatedtocarbon steels,stainlesssteels,highlyalloyedsteels,andferroalloysproduction. This manuscript tries, above all, to be a text dedicated to the university studies forbachelor,master,andpostgraduatestudents.Atthesametime,thebookmightbe an useful instrument for the basic formation of those people interested in working in the ironmaking and steelmaking sector, as well as for the updating of the basic knowledgeofthepeoplethathadknowledgeoftheironandsteelmetallurgy. The manuscript claims to show for the first time in a book of these characteristics, together with the most significative operating variables of the processesandoperationsofthesteelsandferroalloysproduction,numeroussolved exercisesandproblems(morethan80).Thesolvedexercisesandproblemshaveas objectivetoconceptuallysupportthetheoreticalfundamentalsoftheBasicOxygen Furnace (BOF) process, the reactions and operations in the electric furnace, the secondary metallurgy, the practice in the solidification-casting molds, the operationsinthetundish,theoperationsinthehotandcoldplasticdeformationof the metal and the study of all the physical and chemical changes produced in the differentfinishingoperationsandprocesses. Habitually, the number of variables involved in the spontaneity and rate of the operations-processes arenumerous (“bigdata”ifweusethecurrentterminology). We want to set up the basis for the development of models that, supported on the basicsciences,couldprovide-findanswers,withtheminimumnumberofvariables, tothetopicsthatareproposedanddevelopedineachoneofthechaptersofthebook. Ontheotherhand,itisnecessarytoconsiderthattheconstructionofmodels,based ontheprinciples-lawsofthescienceassociatedtotheproposedexercises,leadsto vii viii Prologue the “know-how” typical of the technological development. Definitely, we want to emphasizeinthetruthandthesciencewhentakingdecisions,puttingasideemotions andfeelings. It is possible that, for the professionals and iron and steelmaking specialists, the contents of the seven chapters of the book, for instance, in the process of pig ironrefinement,thefusion-refinementofscrap,theproductionofferroalloysorthe molding,plasticdeformationandfinishingprocesses,mightbelimited.However,in thebibliographythatiscollectedattheendofeachchapter,weincludemonographs andspecificreviewsthatallowthereadertostrengthenknowledgeabouttheconcepts developedinthetext,aswellastoacquireagreaterspecializationthatcouldpropitiate thedevelopmentandtechnologicalchanges. Finally, the authors want to thank Prof. José Antonio Pero-Sanz Elorz because he was responsible for creating the Research Group in Ironmaking, Steelmaking, Metallurgy and Materials of the University of Oviedo in the middle of the last century. We also express our gratitude to Profs. José Pedro Sancho Martínez and ÁngelAlfonsoFernándezoftheUniversityofOviedoandRobertoGonzálezOjeda of the Universidad Panamericana de México for their contributions both in the thermodynamicfundamentalsandinthesimulationandmodelingofprocesses. Oviedo,Asturias,Spain LuisFelipeVerdejaGonzález March2021 DanielFernándezGonzález JoséIgnacioVerdejaGonzález Contents 1 TheBasicOxygenFurnacetoObtainSteel ....................... 1 1.1 SteelintheHistory ......................................... 1 1.2 TheBasicOxygenFurnace:Introduction ....................... 4 1.3 ReactionsintheConverter ................................... 9 1.3.1 ThermodynamicsofSolutions ......................... 9 1.3.2 ThermodynamicsandKinetics ......................... 12 1.3.3 ApplicationoftheCaO–FeO–SiO TernaryDiagram 2 totheStudyoftheLDSlags ........................... 17 1.3.4 SolvedExercises ..................................... 20 1.4 MassandEnergyBalances ................................... 31 1.5 KineticsoftheReactionsintheConverter ...................... 35 1.6 Physical–ChemicalCharacteristicsoftheLDSlags .............. 58 1.6.1 SolvedExercisesandProblems ........................ 65 References ..................................................... 80 2 TheElectricSteelworks ......................................... 83 2.1 Introduction ............................................... 83 2.2 TheElectricFurnace:CharacteristicsandApplications ........... 84 2.2.1 ProductionofPigIron ................................ 85 2.2.2 SteelProduction ..................................... 88 2.2.3 Ferroalloys .......................................... 89 2.2.4 CeramicMaterials ................................... 94 2.2.5 SolvedExercises ..................................... 95 2.3 ProcessesandReactionsintheElectricFurnace ................. 122 2.3.1 Smelting(Fusion) .................................... 123 2.3.2 Refining ............................................ 123 2.3.3 Reduction ........................................... 128 2.3.4 SolvedExercises ..................................... 130 2.4 DesignofElectricFurnaces .................................. 147 2.4.1 CharacteristicsandDevicesoftheFurnaces .............. 148 2.4.2 HeatTransferMechanisms ............................ 152 ix x Contents 2.4.3 SolvedExercises ..................................... 162 References ..................................................... 171 3 SecondaryMetallurgy .......................................... 173 3.1 Introduction ............................................... 173 3.2 Deoxidation ............................................... 174 3.2.1 SolvedExercises ..................................... 180 3.3 Desulphurizing ............................................. 186 3.3.1 SolvedExercises ..................................... 193 3.4 VacuumTreatments.Degasification ........................... 207 3.5 KineticsoftheRefiningProcesseswithInterfaceResistances ..... 215 3.6 Solved Exercises: Vacuum Treatments. Degasification. KineticsoftheRefiningProcesswithInterfaceResistances ....... 217 References ..................................................... 231 4 SolidificationoftheSteel ........................................ 233 4.1 Introduction ............................................... 233 4.2 Molding ................................................... 236 4.2.1 SolvedExercises ..................................... 241 4.3 ContinuousCasting ......................................... 257 4.3.1 Introduction ......................................... 257 4.3.2 TheContinuousCastingProcess ....................... 260 4.3.3 TertiaryMetallurgy:Inclusions ......................... 275 4.3.4 DevelopmentoftheContinuousCasting ................. 288 References ..................................................... 291 5 Hot-WorkingOperations ........................................ 293 5.1 Introduction ............................................... 293 5.2 HotWorking ............................................... 296 5.2.1 FlowStressesintheHighTemperatureDeformation. ConstitutiveEquation ................................. 300 5.2.2 TheHotForming(T >0.75·T ) ....................... 302 H E 5.2.3 Improvements by Hot Forming of Solidification Structures ........................................... 305 5.2.4 BandedStructure(MechanicalFibering) ................ 306 5.2.5 Thermal–Mechanical Treatments with Phase Transformation ...................................... 311 5.3 ForcesandGeometricalRelationshipsinRolling ................ 313 5.3.1 SolvedExercises ..................................... 314 5.4 RollingMills .............................................. 320 5.4.1 SolvedExercises ..................................... 327 5.5 Homogenization Heat Treatment (Soaking): Oxidation andDecarburizingoftheSteel ................................ 360 5.5.1 SolvedExercises ..................................... 365
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