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Control of Slag Formation, Foaming, Slopping, and Chaos in BOF

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Abstract

Decarburization, slag formation, foaming, and slopping in basic oxygen furnace (BOF) can now be partly understood, and to some extent predicted with the help of several on-line measurements and on-line control models. The principal reaction in BOF is decarburization. The bulk of the decarburization takes place in the turbulent region of jet impact irrespective of the fact whether the slag is solid, liquid or foamy. Metal droplets are ejected from the jet impact zone but it is difficult to distinguish the decarburization occurring in the bulk metal from that occurring in the droplets. Slag in BOF is heterogeneous and always contains some entrained gas bubbles and solid material (either un-dissolved or precipitated). At no stage the slag is 100 % liquid. A significant part of the metal droplets fall back and travel through the semi liquid slag. Through this mechanism the droplets can cause slag foaming and slopping in the BOF. Phenomenon of slag foaming and slopping can be monitored and controlled by following, dynamically, the audio signals, gas flow rate and composition, by tracking ‘Chaos’ in chemical reactions, by manipulating the chaotic attractors, and by monitoring the lance water temperature and weight. Relative stability potential (RSP) diagrams are found to be a good indicator of the dynamics of process inside the BOF and help in advance prediction of the impending chaos.

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Acknowledgments

One of the authors (BD) would like to specially thank Mr. Willem van der Knoop of TATA Steel Ijmuiden, and also other researchers for the exchange of knowledge and interesting technical discussions that took place over a long period of nearly 25 years during the colloborative research work at Hoogovens Ijmuiden, CORUS Ijmuiden, TATA Corus, TATA Steel Ijmuiden, TATA Steel Jamshedpur, and Visakhapatnam Steel Plant Visakhapatnam.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Indian Institute of Technology, Kanpur, India

    Brahma Deo

  2. TATA Steel, Ijmuiden, The Netherlands

    Aart Overbosch & Bert Snoeijer

  3. TATA Steel, Jamshedpur, India

    Debasis Das

  4. Visakhapatnam Steel Plant, Visakhapatnam, India

    Karumanchi Srinivas

Authors
  1. Brahma Deo
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  2. Aart Overbosch
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  3. Bert Snoeijer
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  4. Debasis Das
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  5. Karumanchi Srinivas
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Correspondence to Brahma Deo.

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Deo, B., Overbosch, A., Snoeijer, B. et al. Control of Slag Formation, Foaming, Slopping, and Chaos in BOF. Trans Indian Inst Met 66, 543–554 (2013). https://doi.org/10.1007/s12666-013-0306-2

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  • DOI: https://doi.org/10.1007/s12666-013-0306-2

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