School of Engineering

Department of Materials Science and Metallurgical Engineering

Pyrometallurgy NPM 321

Production of stainless steel in an AOD (argon-oxygen decarburiser)
Group 2 27182674 27182330 26279208 27352472

Kubeka SG Ndlovu MT Malinga TR Nkuna MT

15 July 2009 Supervisor: M. Erwee

The Basic Oxygen Furnace (summary)

The pig iron from the blast furnace is purified at the BOF by the addition of fluxes which lower the melting point of impurities for sufficient collection by the slag. Oxygen is also blown at supersonic velocities in order to oxidize certain species like carbon, silicon, manganese, phosphorus and sulfur. Impurities (oxides) are collected as slag. This stage is a pre-decarburization step prior to the production of stainless steel by the Argon and Oxygen decarburiser. After blowing with oxygen, the hot metal (iron) is tapped into a ladle where alloying elements, temperature trimmers and de-oxiders are added, carbon is also added depending on a grade being produced. After tapping, the hot metal is called steel and the slag is poured into the slag pot. Ferro alloys of nickel, chromium, manganese and silicon are also melted with stainless steel scrap in the electric arc furnace. This will be added to steel to yield stainless steel with appropriate amounts of chromium and nickel in an EAF. When the heat composition is within specification, it is further passed to the AOD for treatment where carbon is removed by oxygen and the melt is stirred by argon.

The production of stainless steel by the Argon and Oxygen Decarburiser (AOD).
(i) Phases present

From the blast furnace to the steel plant, only the pig iron (of 4.5%C, O.5%Mn, 0.1%P, 0.08%S, 0.6%Si, 0.07%Ti and Fe as balance) and slag (Al2O3, SiO2 and Fe2O3) exist. De-sulfurisation is the first step at the steel plant where sulfur is removed by soda ash to values about 0.035. After blowing and tapping at the BOF, slag and steel exist where a typical composition of steel is 0.6%C, 0.157%Mn, 0.017%P, 0.0149%S and Fe. The slag composition now has FeO and not Fe2O3. Low C ferrochromium of 69%Cr, 0.1%C, 0.9%Si and 30%Fe is added with 100%Ni and 100%Mn is melted with stainless steel scrap and steel in an EAF. The product is stainless steel of typical composition of 20%Cr, 8%Ni, 0.85%C, 0.9%Mn and 70.3%Fe and slag. This product is passed to the AOD. Oxygen is blown through a lance at 25-60m3/ton of steel and argon at 1-5m3/ton of steel in an AOD. The final phases after the AOD is the stainless steel (of 22%Cr, 8%Ni, 0.025%C, 0.9%Mn and 69%Fe), slag and CO2.

(ii)

Reaction types Reactions occur in both AOD vessel and the EAF and there are as follows:

Melting Reaction Melting of all the feed to make up stainless steel occurs in the EAF, temperature is raised for mixing to be homogeneous consequently increasing rate of reaction, as explained above the product from the EAF will be stainless steel. Steel (molten) + stainless steel (scrap) + low C Ferrochromium (FeCr) + Nickel Briquettes + Ferromanganese (FeMn) Stainless Steel.

Gas/Liquid Reaction In the AOD vessel, oxygen blown by the lance oxidizes chromium in the stainless steel through the reaction: 3/2O2 + 2Cr Cr2O3

Liquid/Liquid Reaction The chromium oxide formed will then be reduced by the carbon in the stainless steel which lead to the formation of CO, the following reaction supports the argument. Cr2O3 + C 2Cr + 3CO

Gas/Gas Reaction The toxic gas CO will reacts with oxygen still blowing out from the lance through post-combustion reaction: CO + O2 CO2 The CO2 is sent to the gas treatment centre. (Hayes, P. pp 144-145)

(iii)

Reactor types

Melting The feed is melted in an EAF unit.

Injection system Oxygen and argon are blown to the liquid stainless steel in the AOD vessel. (Hayes, P. pp 140-144)

(iv) & (v)

Main process variables and process inputs

The heat must be homogeneous in both chemistry and temperature. Sufficient stirring by argon ensures homogeneity in temperature. Pressures of oxygen and argon are 25 60m3/ton of steel and 1 5m3/ton of steel.

(vi)

Aim of the process

The basic aim of the AOD process is to refine stainless steels. Stainless steels are refined by removing carbon through oxidation. The argon introduced in the AOD process sterilises the stainless steel by preventing excessive oxidation of chromium during the decarburization of the stainless steel. The argon also reduces the partial pressure of CO in the bath and thus allowing high chromium level to be in equilibrium with low carbon content. (vii) Type of process

The AOD process is typically a batch process since a vessel is used to facilitate the process. The vessel is typically loaded with stainless steel and then after decarburization through the AOD process the converter is emptied. The increase in demand of stainless steel has lead in investigation into continuous AOD processes. References Fruehan R.J. The making, shaping and treating of steel, 11 th edition, steel making and refining volume, chapter 12.

Hayes P. Process principles in minerals and materials production, 3 rd edition, pp 140 148. Institute for prospective technological studies, Integrated Pollution Prevention and Control Reference Document on Best Available Techniques in the Smitheries and Foundries Industry, July 2004