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Foaming in Electric Arc Furnace—Part II: Foaming Visualization and Comparison with Plant Trials

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Abstract

The kinetics of slag foaming by limestone particles was studied at 1773 K (1500 °C) with the aid of an X-ray imaging system. Two models were implemented to describe the decrease in foam height with the time on the basis of the lowering of the average temperature and CaO shell formation during decomposition reaction. The energy impact of carbonate additions was studied on an industrial scale in a 100-ton electric arc furnace (EAF). It was found that, in the case of the addition of carbonates after the scrap is completely molten, the heat effects for limestone and dolomite (2255 and 2264 kJ/kg, respectively) were only 70 pct from theoretical values. Comparing these values with similar additions during the scrap melting stage shows that the energy requirements in the case of carbonate additions to steel bath are much smaller. It was found from the trial heats with dolomite addition to the steel bath that the partial substitution of lime by raw dolomite can be made without an increase in energy consumption.

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Abbreviations

Q :

the amounts of energy (J)

S :

surface area (m2)

T :

temperature (K)

R :

sphere radius (m)

R c :

crucible radius (m)

r :

distance to the sphere center (m)

t :

time (s)

κ :

thermodiffusivity coefficient (m2·s−1)

K :

thermal conductivity (W·m−1·K−1)

ρ :

density (kg·m−3)

C p :

heat capacity (J·kg−1·K−1)

q :

specific heat of carbonate decomposition (J·kg−1)

V f.l :

the volume of foaming layer (m3)

h :

the depth of slag bottom layer (m)

N :

number of limestone granules in sample added

v :

rate of carbonate decomposition (m·s−1)

k d :

decomposition rate constant (m·s−1)

E a :

activation energy of limestone decomposition (J·mol−1)

P :

porosity

β :

pore shape factor

μ :

slag viscosity (Pa·s)

ξ :

the volume fraction of solid particles

t Q :

parameter, characterizing the relative time of carbonate addition in relation to whole heat duration (pct)

p i :

i parameter value for a certain heat

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Acknowledgments

The authors are thankful to the Swedish Institute (SI) and Swedish Strategic Foundation for Environmental Research (MISTRA), project no. 88032 financed via Swedish Steel Producers Association (Jernkontoret) for the financial support, and to Professor A.K. Lahiri for fruitful discussions and suggestions.

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Authors and Affiliations

  1. Royal Institute of Technology (KTH), 100 44, Stockholm, Sweden

    Andrei Chychko (Researcher, Research and Development Engineer)

  2. PEARL Lab, Erasteel Kloster AB, 81582, Söderfors, Sweden

    Andrei Chychko (Researcher, Research and Development Engineer)

  3. Department of Materials Science and Engineering, Royal Institute of Technology, Brinellvägen 23, 100 44, Stockholm, Sweden

    Lidong Teng (Docent)

  4. Royal Institute of Technology, Brinellvägen 23, 100 44, Stockholm, Sweden

    Seshadri Seetharaman (Professor Emeritus, Mercator Visiting Professor)

  5. Institute for Iron and Steel Technology, TU-Bergakademie, 09599, Freiberg, Germany

    Seshadri Seetharaman (Professor Emeritus, Mercator Visiting Professor)

Authors
  1. Andrei Chychko
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  2. Lidong Teng
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  3. Seshadri Seetharaman
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Corresponding author

Correspondence to Andrei Chychko.

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Manuscript submitted March 30, 2010.

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Chychko, A., Teng, L. & Seetharaman, S. Foaming in Electric Arc Furnace—Part II: Foaming Visualization and Comparison with Plant Trials. Metall Mater Trans B 43, 1078–1085 (2012). https://doi.org/10.1007/s11663-012-9690-y

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