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Advanced Melt Metallurgy

Production of advanced steels and ferroalloys with


secondary metallurgy units

Ville-Valtteri Visuri
Laboratory of Process Metallurgy
University of Oulu

Contents
Introduction and research motivation
Holistic process oriented models
New concepts for producing advanced steels
Publications

22.11.2013

Introduction and research motivation


Growing demands for energy and material efficiency, along
with economical competitiveness
New advanced modelling platforms are developed that allow
coupling of chemical reactions and physical transport
phenomena in steelmaking
Explicit focus on main processes in melt metallurgy of
steelmaking
AMMe brings together major players in the related steel
industry and academia

22.11.2013

Holistic process oriented models


Objective:

22.11.2013

Create a set of holistic process oriented models


describing certain phenomena similar to all unit
processes in secondary metallurgy simulate
process practice in case specific studies.

Studied processes
Primary metallurgy

Argon-Oxygen Decarburisation

Basic Oxygen Furnace

Secondary metallurgy

Vacuum tank degasser


22.11.2013

CAS-OB

Studied processes
Phenomena-based modules for AOD and CAS-OB
Plane geometry

reactions between steel and top-blown gas

Droplet geometry

reactions between steel droplets and slag


reactions between steel and slag droplets

Bubble geometry

reactions between steel and gas bubbles

Argon-Oxygen Decarburisation
22.11.2013

CAS-OB

Studied processes
CFD-based approaches for VD and BOF
VD model

CFD model with denitrification and desulphurisation

BOF model

fast 2-D fluid flow model with main reactions

Vacuum tank degasser


22.11.2013

Basic Oxygen Furnace

AOD Converter Process Simulator


A fast phenomena-based numerical model
Modular structure: sub-model for each processing stage
Can be used to improve blowing practice as well as timing and
quantity of additions

Schematic illustration of the modular structure.

Predicted C and Cr content versus steel samples.

V.-V. Visuri, M. Jrvinen, P. Sulasalmi, E.-P. heikkinen, J. Savolainen and


T. Fabritius, ISIJ Int. 2013, 53(4), 603.

S. E. Pisil, M. P. Jrvinen, A. Krn, T. Ikheimonen, T. Fabritius and


P. Kupari, Steel Res. Int. 2011, 82(6), 650.

22.11.2013

CAS-OB Simulator
A fast phenomena-based
numerical model for chemical
heating
Accurate prediction of heating
rate and steel composition
A tool for
1. improving energy efficiency
2. optimisation of alloying practice
3. Improving refractory campaign

Schematic illustration of the CAS-OB model.


M. Jrvinen, A. Krn, S. Ollila and T. Fabritius, SCANMET IV, 2012.

Oxygen efficiency and the fraction of O2 used to oxidise Al.


M. Jrvinen, A. Krn, S. Ollila and T. Fabritius, SCANMET IV, 2012.

22.11.2013

Vacuum tank degassing model


A numerical model for simulating
hydrogen and nitrogen removal in
vacuum degassing
Can be used to optimise gas flow
rate and deep vacuum time for
advanced steel grades
3D diagrams have been
developed and validated for fast
prediction of final nitrogen
content
Industrial case: nitrogen control
has increased by increasing the
deep vacuum time and by
optimising alloying of steel
22.11.2013

3-D graph for fast prediction of final nitrogen content.


Courtesy of S. Yu.

New concepts
for producing advanced steels
Objective:

22.11.2013

Develop new concepts to produce advanced


steels and ferroalloys with unit processes in
secondary metallurgy

Electrolytic extraction method


Electrolytical
dissolution

Inclusions are selectively dissolved


from the steel matrix
Quantity, morphology and elemental
composition of the inclusions are
determined semi-automatically with
SEM
Effect of inclusion population on
mechanical properties of final
product, e.g. bendability
Sophisticated inclusion control for
advanced steels
Industrial case: comparison of steel
sampling methods, improving steel
cleanliness by optimised calcium
treatment
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Filtering

SEM-analysis
A spherical Al-Ca-Mg-O-S inclusion

Methodology

Inclusion size distribution in three processing stages at


Ruukki Metals
A. Mkel, FIMECC Result February 2012.

Industrial case at Ruukki Metals Oy

Improvement of BOF bottom stirring


Approx. 30 % increase in lifetime of
the bottom stirring and increased total
lining lifetimes
Methods for improving the bottom
stirring included:
1. new bottom gas valve controls
2. implementing multi-hole plugs
3. improving workers competence
4. increasing temperature accuracy
Plenty of work is still needed to
maintain a 2500 heat lifetime and 100
percent availability of bottom stirring

22.11.2013

Lifetime of the bottom stirring, lifetime of the lining and


availability of the bottom stirring for different campaigns.

Industrial case at Outokumpu Stainless Oy

Ferritic Ti+Nb alloyed steel grade


Development work has been done at
Outokumpu Stainless for improving
processing of different steel grades
Grade 1.4059 acts as an excellent
example for process development
done through different trials.
Results show that average cast
length is increased and amount of
single heat casts has decreased.
Latest practice enables ability to cast
sequences up to 5 heats.
In general, it can be stated that
productivity, yield and quality have
improved.
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Improvement in heats per cast at Outokumpu Stainless Oy

Improvement in cast sequences at Outokumpu Stainless Oy

Publications
Year

Journal
papers

Conference
papers

2009

Masters
theses

Bachelors
theses

Reports
and
posters

2010

2011

2012
2013

10

In press

Total

14

22.11.2013

Total

1
1

7
10

10

12
1

15

41

Thank you for your attention

Contact information
Ville-Valtteri Visuri
Laboratory of Process Metallurgy
University of Oulu
PO Box 4300 | FI-90014 University of Oulu | Finland
ville-valtteri.visuri@oulu.fi
22.11.2013

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