Future steelmaking technologies and the role of basic research

Abstract

The steel industry is going through a technological revolution that will not only change how steel is produced but also the entire structure of the industry. The drivers for the new or improved technologies, including reduction in capital requirements, possible shortages in raw materials such as coke and low residual scrap, environmental concerns, and customer demands are briefly examined. The required response of the industry to these drivers will be new processes such as direct ironmaking, near net shape casting, and those to improve charge materials to the electric arc furnace (EAF).

The know-how for these process improvoeemnts and revolutionary technologies can be purchased, if it exists. However, since the U.S. industry has a unique set of drivers, it may be necessary to develop many of the new technologies through its own research and development. The current status of research and developoment in the United States and selected international producers was examined. As expected, it was found that the industry’s research capabilities have been greatly reduced. Furthermore, less than half of the companies that identified a given technology as critical have significant research and development programs addressing the technology. It is clear that, in many cases, these technologies must be developed collaboratively using all of the intellectual resources available, including universities. Much of the basic process understanding and data for optimization can be obtained from basic research, which is highly focused on the requirements of the new process, thus eliminating some expensive pilot plant trials.

Examples of how basic research aided in process improvements in the past are given. The examples include demonstrating how fundamentals of reaction kinetics, improved nitrogen control, and thermodynamics of systems helped reduce nozzle clogging and how fluid flow studies reduced defects in casting. However, in general, basic research did not play a major role in processes previously developed but helped our understanding and aided optimization. To have a major impact, basic research must be focused and be an integral part of any new process development. An example where this has been done successfully is the AISI Direct Ironmaking and Waste Oxide Recycle projects, in which fundamental studies on reduction, slag foaming, and postcombustion reactions have led to process understanding, control, and optimization. Industry leaders recognize the value and need for basic research but insist it be truly relevant and done with industry input. From these examples, the lessons learned on how to make basic research more effective are discussed.