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CHAPTER 4

STEEL PROCESSING IN ENERGY OPTIMIZING FURNACE

4.1 PREPARATION OF EOF

The EOF process is essentially basic oxygen steel making process

using combined side blowing. After the previous heat is tapped, the EOF
refractory is inspected, and the weak areas are repaired with refractory
material using a pneumatic gunning machine. The submerged tuyere
condition is inspected and wherever required the tuyeres pushed or changed
as the situation demands. The tap hole is inspected and cleaned using oxygen
lancing. There after the tap hole is blocked with carbon coated magnesite peas
using a pneumatic gunning machine. The readiness of all the systems of the
EOF is checked in the computer screen and once all systems are found in
order, clearance is given to start the process. First, oxygen blowing through
the submerged tuyeres is started and then pre-heated scrap is discharged from
the SPH fingers into the EOF.

4.2 EOF CHARGING

Thereafter, the fingers are closed and the sliding door on top of the
EOF is opened and scrap is charged using the specially designed scrap bucket
with the help of EOT crane. The EOF hearth is lined with basic refractory, in
which 20% pre-heated scrap is charged followed by 80% liquid iron is poured
through the hot metal launder using the hot metal charging crane. During the
hot metal pouring, lime is added into the EOF through the automatic feeding
system such that it melts during the hot metal pouring.
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4.3 OXYGEN BLOWING

Oxygen blowing into the EOF through submerged tuyeres,

atmospheric injectors and supersonic lances take place following a specified
oxygen blow profile shown in Figure 4.1

OXYGEN BLOW PROFILE

80

70 Atmospheric Injector
60

50

40

30
Submerged tuyere
20 Supersonic Lance Hand Lance
10

0 5' 10' 15' 20' 25' 30' 35' 40'

TIME IN MINUTES

Submerged Tuyere - 4 Nos @ 20Nm3/min = 700Nm3

Atmospheric Injector - 4 Nos @ 55Nm3/min = 1760Nm3
Supersonic Lance - 1 No @ 20Nm3/min = 340Nm3
Hand Lance - 1No @ 10Nm3/min = 150Nm3
Total = 2950Nm3 (45 MT Heat size) A verage Cons. 65Nm3 per MT of S teel

Figure 4.1 Oxygen blow profile – 45 MT EOF

The main concept of EOF is to introduce oxygen below the bath to

react with carbon in the melt. Dissolved gases are purged from the refining
bath as the carbon monoxide gas bubbles produced by the carbon-oxygen
reaction rise towards the liquid bath surface. Further oxidation of elements
occur as the gas bubbles break the liquid surface and throw molten metal into
the oxidizing surface atmosphere above the bath. Carbon monoxide and
Hydrogen gases escaping from the bath are subsequently oxidized to carbon
di-oxide and water vapour above the bath by the oxygen provided through
atmospheric injectors within the furnace vessel. The latent heat of the hot
metal and the heat generated from the oxygen reaction is efficiently used to
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raise the temperature of the bath and melts the scrap. The carbon required for
the reaction is introduced through the hot metal and partly by solid pig iron.
The submerged oxygen blowing through the tuyeres and supersonic lance
helps to create a very strong turbulence in the steel bath that facilitates in
achieving the short blowing periods. Sources of oxygen blow are listed along
with their respective average yield in terms of carbon removal from the bath,
generating CO are shown in Table 4.1 hereunder:

Table 4.1 Sources of oxygen blow in EOF

Sources of Generation Available

No. O2 Flow Yield*
Oxygen Blow CO O2
Nm3/min % Nm3/min Nm3/min
Submerged
4 4 x 5 = 20 100 40 -
Tuyeres
Injectors 4 4 x 18 = 72 60 86 29
Supersonic
2 2 x 20 = 40 90 72 4
Lances
False air (500
105 25 54 78
Nm3/min)
Total "Soft" blow 197 45.7 180 107
Total "Hard" blow 237 53.2 252 111

Note: 1. *Hard blow is same as 'soft' blow plus SS lances.

2. The 'yield' varies along the blow as a function of liquid metal
analysis, temperature, slag analysis and fluidity, availability of
false air etc.
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4.4 MELTING PRACTICE

During the melting process, high silica slag is continuously flushed

out through the slag door in order to facilitate high degree of de-
phosphorization at basicity levels of 2.8 to 3.0. As the carbon content of the
bath reduces from 4.2% to 0.15%, the bath temperature is increased to 1650ºC
(Figure 4.2 and 4.3).

(Min)

Time

Figure 4.2 Blow time Vs Temperature

(Min)
( C)
Time

Figure 4.3 Decarburization of hot metal

The carbon percentage is checked through quick carbon analyzer and
the temperature is also checked through disposable temp-tips during the steel
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processing. As soon as the tapping temperature and desired carbon level in the
bath is achieved, the tap hole is opened using oxygen lancing and steel free
from oxidizing slag is tapped into the steel ladle. During tapping, primary de-
oxidation of steel is carried out with the addition of aluminium and silico-
manganese. The reducing slag is formed using lime and fluxes to facilitate
subsequent secondary refining process. Typical blow period of EOF is 30/35
minutes and tap–to–tap time is 45/50 minutes as shown hereunder:

Refractory repair 5
Scrap charging 2
Hot metal charging 5
Oxygen blowing 30
Tapping 5
Reserve Time 3
Total 50

The EOF heat balance for steel bath and furnace atmosphere is
shown in Table 4.2. EOF is an energy efficient oxygen steel making process.
It utilizes the energy available from the three following sources:

a) Chemical energy released in the molten bath from reactions

between the injected oxygen and oxidizable elements in the
molten metal including added carbon.

b) Chemical energy from gaseous oxidation reactions in the

furnace above the molten bath. These involve oxygen reacting
with the effluent carbon monoxide and hydrogen gases from
the molten bath.

c) Sensible heat transfer from the hot effluent furnace gases to a

cold scrap charge in a scrap preheater.
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Table 4.2 Energy optimizing furnace - heat balance - bath and

atmosphere

Heat Input
Mcal/ ton of
Mcal/heat
steel

1. Hot Metal Enthalpy 6.274 203.5

2. Pig Iron Enthalpy 0.242 7.8
3. Steel Scrap Enthalpy 427 13.9
4. Iron Scrap Enthalpy 661 21.4
5. HBI/DRI Enthalpy 0 0
Sub- Total 7.603 246.6

6. Carbon Oxidation in the Bath 3.284 106.5

7. Carbon Oxidation in the Atmosphere 3.647 118.3
8. Silicon Oxidation 1.607 52.1
9. Manganese Oxidation 0.235 7.6
10. Phosphorous Oxidation 0.201 6.5
11. Iron Oxidation 1.961 63.6
12. Sulphur Oxidation 6 0.2
Sub-Total 10.941 354.9
TOTAL 18.544 601.5

Heat Output
Mcal/ton of
Mcal/heat
steel
1. Liquid Steel Enthalpy 10.532 341.6
2. Slag Enthalpy 2.726 88.4
3. Gas Enthalpy 1.914 62.1
4. Dust Enthalpy 1.08 3.5
5. Heal Losses through Panels 1.408 48.6
6. Heat Losses through Refractories/door 1.817 58.9
TOTAL 18.595 603.2
Difference Input-Output -51
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The liquid hot metal poured in the EOF benefits the process from
the viewpoint of chemical energy as stated above as well as the enthalpy of
hot metal itself.

4.5 ADVANTAGES OF EOF

EOF has following advantages with regard to steel process and

quality:

1. Low Energy Consumption

2. High Productivity

3. Low tramp elements as input is 80% hot metal, and balance

solid charge free from tramp elements.

4. Oxygen potential in the bath is approximately 300-400 PPM,

since carbon opening is favorable.

5. Alloy recovery in primary de-oxidation is better.

6. Better phosphorous control keeping basicity of the slag

between 2.8 to 3 with continuous lime feeding and de-
slagging. Slag-metal reaction is better due to vigorous
turbulence inside the bath due to oxygen blowing through
submerged tuyeres.

7. Slag free tapping as the tap hole is located in the lowest

portion of the bottom and fast tilt back system.

8. Opening carbon control is better through catch carbon

practice.

9. Low nitrogen potential in steel due to the facility of change

over from nitrogen to argon in tuyeres prior to tapping.
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10. Flexibility in charge mix from 100% to 70% of hot metal and
rest cold charge. Sponge iron feeding continuously through
conveyor is also possible.

The key factors of EOF process are simplicity of operation, low

capital and operating costs, flexibility in raw material usage and good de-
phosphorization capability. The EOF uses lower cost energy and utilizes this
energy more efficiently. The EOF is a steel making technology for the 1990s
and beyond.