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Optimization of Desulphurization of Hot Metal and Liquid Steel For RAIL

This document summarizes efforts to optimize desulphurization of hot metal and liquid steel for rail production. Sulfur content in rail steel must be very low, below 0.025%. Trials were conducted using deep injection of calcium carbide and magnesium reagents to reduce sulfur in the ladle from an average of 0.035% to 0.01%. Further reductions were achieved by adding synthetic slag and controlling slag skimming. After two phases of trials, sulfur content was reduced on average to 0.015% through optimized desulfurization practices and synthetic slag addition was reduced.

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96 views16 pages

Optimization of Desulphurization of Hot Metal and Liquid Steel For RAIL

This document summarizes efforts to optimize desulphurization of hot metal and liquid steel for rail production. Sulfur content in rail steel must be very low, below 0.025%. Trials were conducted using deep injection of calcium carbide and magnesium reagents to reduce sulfur in the ladle from an average of 0.035% to 0.01%. Further reductions were achieved by adding synthetic slag and controlling slag skimming. After two phases of trials, sulfur content was reduced on average to 0.015% through optimized desulfurization practices and synthetic slag addition was reduced.

Uploaded by

ratul_sarkar
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© Attribution Non-Commercial (BY-NC)
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Optimization of

desulphurization of hot
metal and Liquid steel
for RAIL
By
A.Chatterjee
S. K Gupta
C. S. Vishwanathan
S. K. Srivastava
RDCIS,SAIL Ranchi
Introduction
o SMS-II,BSP produces 2.8Mt through
MixerDe-SConverterARULF/RHCC(Slab)
MixerDe-SConverterARU
VAD/LF/RHCC(Bloom,Rail)
o Major products includes
• Rails : long rails, crane rails
• Plates
• Light and heavy structural
o BSP is committed for superior quality of steel and hence
installation of De-S unit (Oct’2007 by Danieli Corus)was
done which is based on co-injection of Mg-CaC2 reagent.
Rail Steel
o Rail Steel requires stringent chemical composition

C: 0.65-0.7%.

Si:0.2-0.25%.

S <0.025%

Al <0.01%

H <1.6ppm
o Though S requirement is <0.025% ,however even
lower S% is required for superior casting properties.
Deep Injection De-S
Benefits

•It helps in Reducing the constraints faced in the raw


material selection for Blast Furnace Operations
-S in Coke, fluxes, ores
• Ensures Lower percentage of S in Products
•Helps in the Overall Cost Reduction
•In Steel Making
- Allows use of cheaper scrap
- Lower Flux rate – higher scrap charge
- Consistent ‘S’ - high strike rate in Steel Making
•Improves Casting speed
Roadmap

 Sulphur mapping during downstream processes.


 Determining efficiency of ladle desulphurization.
 Improvement in Slag skimming efficiency
 Control of Sulphur pickup in BOF.
 Steel De-S by using synthetic slag.
 Optimization of Sulphur control in each unit.
RAIL STEEL
0.035
0.032

0.03

0.025 0.024

0.021
0.02 0.02
% S

0.017

0.015 0.015

0.01

0.005

0
HM BOF Bath ARU LF In LF out Tundish
Stage

Sulphur mapping for rail heats in BOF-ARU-LF-CC route (Previous practice)


Desulphurization process
parameters
Operating Specification
Parameters
N2 flow rate 30 – 50 Nm3/hr
CaC2 : Mg reagent 5:1
ratio
Avg. CaC2 160 kg/heat
consumption
Avg. Mg 30 kg/heat
Consumption
Avg input [S] 0.035 %
Avg post deS [S] 0.01 %
Avg %S drop 70 %
Avg injection time 5 min.
Slag skimming practice& S
Pickup in BOF
Sl Initial Initial Final [S] Final Ladle Lip BOF Bath
No [S] Slag (after Slag Condition / [S]
(%) Depth DeS) Depth jamming (%)
(cm) (%) (cm)
1 0.04 9 0.01 4 Ok 0.014

2 0.04 - 0.01 5.5 Ok 0.013

3 0.04 12 0.011 7.5 High 0.015

4 0.039 11.5 0.019 6.5 Slightly 0.02


Desulphurization of steel
by synthetic slag
o Synthetic slag : CaO – Al2O3 compound
• Forms CaO – Al2O3 – SiO2 type refining
slag.
• Increases S partition Ratio.
• Requires adequate De-oxidation level.
o De-S depends on
• Activity of oxygen
• Circulation rate in bath
Optimisation of Ladle steel
De-S
Nomogram 1 Nomogram 2

Bath Sulphur Addition of Bath Sulphur Addition of


(%) Synthetic slag (%) Synthetic slag
(kg/heat) (kg/heat)

Upto 0.018 Nil Upto 0.015 Nil

0.019 – 0.021 300 0.016 – 0.020 300

0.022 – 0.024 400 0.021 – 0.025 500

0.025 & above 500 0.026 & above 600


Trial Results
0.045
0.04
0.035 0. 034

0.03
% Sulphur

0.025
0. 021
0.02 0. 018

0.015 0. 016
0. 015
0. 014

0.01 0. 011

0.005
0
HM HM Post BOF Bath ARU LF in LF out Tundish
DeS
Stages

Sulphur mapping for rail heats with synthetic slag addition


Trial Result continued
0.055
0.05
0.045
0.04
0.035 0.035
% Sulphur

0.03
0.025
0.02 0.018 0.018
0.016
0.015 0.015
0.013
0.01 0.01

0.005
0
HM HM Post BOF Bath ARU LF in LF out Tundish
DeS
Stages

Sulphur mapping for rail heats without synthetic slag addition


Trial Summary
Phase-I:
o 46 trial heats.

o Based on nomogram-1.

o Average final S: 0.017%( >0.02% in 3 heats)

Phase-II:
o 20 trial heats.

o Based on Nomogram-2.

o Average final S: 0.015%( >0.02% in 1 heats)


Results & Conclusion

 Control of S <0.015%.
 Proper slag skimming to control S pickup in
BOF within 0.005%.
 No synthetic slag additions for S in steel
<0.015%.
 Reduction in Synthetic slag addition(from
323kg/heat to 242kg/heat).
 Average final S was found to be 0.015%
Thank you

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