MANUFACTURING OF

STAINLESS STEEL
STEEL.
AOD - SLAG IMPROVEMENT
FURNACE IMPROVEMENT

STAINLESS STEEL MELTING SHOP

El t i A
Electric
Arc Furnace.
F

ASM (Top & Bottom Blowing)

Blowing).

Ladle Refining Furnace.

Caster.

Induction Furnace.

STAINLESS STEEL PRODUCT

GRADES

SLAB

BLOOM

304, 304L, 316, 316L,

409M 430,
409M,
430 410S
410S,

TSL-AUS, T1, T2, T3, T4

T5, T6, T7

Because conditions are not the same

throughout the lining...
in other words, the rate at which
different areas of the lining are worn
away varies

Cone

1 mm/cast

Tap
T
Side

2 mm/cast
5 mm/cast
/

10 mm/cast
3 mm/cast

Slag
Line

Tuyere Zone
Floor

CHARGE MIX
MATERIALS

MS SCRAP
S.S SCRAP
S S UTENSILS
S.S
HC FERRO CHROME
RETURN SCRAP
B LIME
B.

RAW

ELECTRIC ARC FURNACE Reference

NOMINAL CAPACITY
ELECTRODE DIAMETER
TRANSFORMER RATING
SHELL DIAMETER
PRIMARY POLLUTION FAN
MOTOR
SECONDARY POLLUTION
FAN MOTOR

40 MT
18 INCH
24 MVA
4300 MM
900 MW
900 MW

The combination of technical

support and the appropr
appropriate
ate
lining design leads to

OBTECTIVE

Balanced Wear
=
Minimum Cost/t

Computer slag models are used to calculate the composition of slags

and to recommend changes to the customers operations...in order
to create a balanced,
balanced optimised slag

Refractory
Oxides

All slags comprise refractory

components i.e.high melting
point,
p
such as CaO and MgO

Fluxing
Oxides

and

fluxing components i.e.low

melting point, such as SiO2,
FeO, Al2O3 and CaF2

A balanced slag provides optimum conditions for steelmaking and refractory

protection

Definition an optimised slag is saturated with appropriate oxides (usually

CaO and/or MgO) with a viscosity similar to paint
Sometimes the slag can become unbalanced due to variations in raw
material compositions or steelmaking operations
If the slag becomes
oversaturated - i.e. contains
excess CaO or MgO viscosity
will increase and the slag may
even solidify

Fluxing
Oxides

Refractory
Oxides

Oversaturated slags provide refractory protection but create handling

problems for the steelmaker

If the balance shifts the other way the slag will be unsaturated i.e.
contains insufficient CaO or MgO
viscosity
y will
w decrease and the
slag may become too fluid
like water

Refractory
Oxides

Fluxing
Oxides

Reactions between refractories and unsaturated slags are the prime cause of lining
wear

Lime versus Doloma

Benefits of Lime:
More readily available
Less lime required during decarburization step
if Al2O3 and
d Nb2O5 levels
l
l are llow
Drawbacks of Lime:
Fluorspar
Fl
additions
dditi
would
ld be
b required
i d if M
MgO
O
or Al2O3 levels of the slag is low to rapidly and
completely dissolve the lime in the reduction
slag

Lime dissolution

Unreacted Lime Particle

Intermediate C2S layer
Partially liquid CS layer

melting point of C2S (Ca2SiO4) = 2130

2130C
C

Fluorspar additions are therefore required

to accelerate the dissolution of C2S

Lime versus Doloma

Benefits of Doloma:
Easier to dissolve during the reduction step
Could improve refractory performance if the
Al2O3 and
d Nb2O5 levels
l
l are hi
high
h
Less or no fluorspar required for dissolution
D
Drawbacks
b k off D
Doloma:
l
More doloma than lime could be required to
achieve a solid decarb slag
Doloma is not as readily available as lime is

Doloma dissolution

Unreacted Doloma Particle

Partially liquid CaMg silicate

(Ca.Mg.Silicates melt < 1450C)

Reduction Slags

STEEL MELTING SHOP

LRF

Balance of refractory and fluxing oxides

Refractory Oxides

(CaO & MgO)

Fluxing
g Oxide

(SiO2)

Slags
g on the liquidus line are on the
pivot point of the balance

Insufficient Shroud Gas Flow i.e. not enough cooling = Small Knurdles

Ideal ~75mm long x ~50mm diameter

Ideal...~75mm

Too Much Cooling...Big Knurdles...could block)

Blocked Knurdle...gases blowing back on to tuyere & surrounding bricks

Knurdle Growth

PROCESS IMPROVEMENT IN
AOD

INTRODUCTION
Effect of different alloying elements on properties of
stainless
t i l
steel
t l
Difference between Ferrite Factor & Ferrite content
Effect of ferrite content on steel quality
Basic Theory of AOD
Chemical reactions occurring during refining
Mathematical
M th
ti l calculations
l l ti
Factors affecting AOD lining
Features of computerized log sheets

Effect of Different Alloying Elements

(A) Chromium:
1. Increases hardness and strength and reduces the elasticity
slightly.
slightly
2. Improves resistance to heat and non-scaling properties
3 High quantity
3.
q antit of chrome and carbon in stainless steel leads
to the formation of chromium carbide precipitate, which
gives the steel
steel, wear resistance property
property.
4. The yield strength also increases by at the lower rate and
notch impact value decreases.
5. The welding properties decreases with increase of chrome
content in steel

 (B)Nickel
1.It raises the strength of steel, but less than
g
does.
what silicon or manganese
2.It acts as austenite stabilizer in austenitic
stainless steel.
3.It does not affect the elasticity of the steel.
4 Ni iimproves th
4.Ni
the notch
t h iimpactt value,
l
and
d
especially at low temperature.
5.It improves scaling resistant properties and
also heat resistant property.

 ( C) Manganese
1.Improves strength of steel with slightly impairing
y
its elasticity.
2.It improves forging and welding properties.
3 Mn along with carbon increases the wear
3.Mn
resistance substantially.
4 I high
4.In
hi h nickel
i k l stainless
t i l
steel
t l 5% off manganese iis
necessary in order to dissolve enough nitrogen
and
d tto give
i steel
t l austenitic
t iti structure.
t t

(D)Molybdenum
1.
Improves both the tensile strength as well as yield
strength.
t
th
2.
Heat resistance property and welding properties also
get enhanced in 316 Stainless steel
steel.
3.
It has higher affinity for carbon than chromium so it
p
the corrosion resistance p
property
p y by
y
improves
combining with carbon and avoiding sensitization.
(E) Carbon
1. It improves the hardening property of martensitic
stainless steel.
2 It improves
2.
i
both
b th yield
i ld stress
t
and
d ttensile
il strength
t
th off
steel.
3 Increase in carbon content reduces the elasticity
3.
elasticity,
forging, welding and cutting properties.
4. carbon content has no effect on the corrosion

(F) Nitrogen
1. In austenitic steels, it stabilizes the structure increases he
h d
hardness
especially
i ll th
the yield
i ld point
i t as wellll as mechanical
h i l
properties at high temperature.
2 It also allows the achievement of high surface hardness
2.
through nitride formation during nitriding.
g is harmful because of lowering
g of toughness
g
durin
3. Nitrogen
the precipitation of nititides.
(G) Copper
1.
It raises the strength and the yield point of steel.
2.
It guarantees austenitic type structure in low nickel
austenitic
t iti stainless
t i l
steel.
t l
3.
High amount of Cu i.e. greater than 4% detoriates the
forgeability of these steels
steels.
4.
Cu has approximately 40% of the austenizing effect of
nickel.

(H) Sulphur
1.
It decreases the hot ductility as it produces hot
shortness
h t
att high
hi h ttemperature.
t
(I) Phosphorous:
Ph
h
1. It causes segregation during the solidification of welds
and hot tearing phenomena
phenomena, which may consequently
occur while the welds, are cooling.
(T) Silicon
1. It is kept less than 1% to prevent the formation of ferrite
and have satisfactory behavior of steel during pickling.
2. Low amount of silicon causes the formation of olivinetype oxide
oxide, which impairs the hot workability and causes
surface finish problems.

(K) Titanium
1.
Strong carbide former.
2.
Acts as stabilizing elements in stainless steel to
improve intergranular corrosion resistance.
3
3.
It also
l helps
h l iin grain
i refinement.
fi
t
(L) Niobium:
1. It acts, as stabilizer more effective than Titanium but it
is costlier as compared to Titanium
( ) Vanadium:
(M)
1.
It improves hot hardness and reduces the grain
growth.
2.
It is used in tool steel to improve the cutting property.
3.
It is strong carbide former and increases the tensile
t
th d i ld i t

(N) Boron
1. When used with 18/8 stainless steel can
help in achieving high elastic limits with the
process of p
p
precipitation
p
hardening.
g
(O) Aluminum:
1.
Strongest deoxidiser.
2.
Increases the strength of steel by the
formation of AlN precipitates, it also helps
in achieving smaller grain size.

Ferrite & Austenite Stablizers

Ferrite Stabilizer

Austenite Stabilizer

Cr

Ni

Si

Mn

Mo

Nb
b

Ti

Cu

Ferrite Factor
Ferrite Factor in the cast state is ratio of Cr
equivalent and nickel equivalent.
where ,
Chromium Equivalent= %Cr+1.5(%Si)+%Mo
Nickel Equivalent= %Ni+0.5(%Mn)+
21%C+11.5%N+0.44%Cu

% Ferrite
% Ferrite is the amount of delta ferrite present in the
austenitic stainless steel.
It is given by the following empirical relationship:
%
Ferrite=119.56*(1.397(%Ni+0.5*%Mn+30*(%C+%N)
+%Cu+39.67) /(%Cr+1.5*%Si+%Mo+19.52))

AOD
Argon Oxygen Decarburization
IMPORTANT FEATURES OF AOD
Reduction in partial pressure of CO
Combined blowing practice (top+bottom
blowing)

Chemical Reactions occurring in

AOD
[C] + 1/2(O2)g = (CO)g
[Si]
[Si]+ (O2)g = (SiO2)s
3[Cr] + 2(O
( 2)g = ((Cr3O4)s
[Mn] + (O2)g = (MnO)s
[Fe] + (O2)g = (FeO)s

CRE
Carbon Removal Efficiency

O 2 usedforC
CRE
O 2 blown O 2 reactedwit hSi

Temperature rise through Oxygen

distribution
C

Temperature rise (oC/%

element)
110

Si

320

Cr

250

Fe

50

Mn

80

Al

400

Oxygen used for oxidation

Coolent Effect
Addition

Cooling (oC/% addition)

Sponge Iron

20

HC FeCr

26

HC FeMn

21 5
21.5

Lime/Dolime

30

FeNi

16

Reduction Mixture Calculation

O2Need to be removed= (O2blown- O2used for C oxidationO2used for Si oxidation)
Amount of Si needed = O2Need to be
removed*1.25
Si reqd. for alloying = (% alloying)*(Wt
alloying) (Wt of
metal)/100.0
So total pure Si required is the sum of
above two factors.
If FeSi
F Si 70% iis used
d th
then, F
FeSi
Si reqd
d=T
Total
t l
Si needed/0.70

Slag Basicity
Slag basicity, B = Wt of CaO/Wt of SiO2
Slag basicity must be maintained at 1
1.7
7 during the
reduction period.
Along
Al
with
ith thi
this th
the %M
%MgO
O should
h ld b
be 8
8~9%
9%
Sources of Si to be considered during Lime
calculation
p
g Si

Opening

Si from FeCr

Si from FeMn

Si from FeNi

Basicity Calculation
1.250 kg Si + 1 nm3 O2 = 2.678 kg SiO2
The slag basicity is expressed as,
B=CaO/SiO2
If the basicity of slag is adTusted on 1.7
then
2.68 kg of SiO2*1.7= 4.6 kg CaO
2.68 kg SiO2 which is produced with 1 nm3
of O2, are neutralised with 4.6 kg of CaO

ASM VESSEL LIFE

Transfer slag from EAF should be minimum
Control
C t lT
Transfer
f silicon
ili
from
f
EAF tto 0
0.3%
3%
max.
Control
C t l HC F
FeCr
C addition
dditi in
i ASM b
below
l
600kg.
The
Th ttemperature
t
d
during
i th
the reduction
d ti
period should be < 16800 C.
Maintain
M i t i slag
l b
basicity
i it > 1
1.7
7 and
d kkeep M
MgO
O
around 8%.
Control
C t l reduction
d ti mixture
i t
addition
dditi tto ttap
time below 20 minutes.

Thank you
Compiled by :
Rajiv Arora