Estimation of Best Combination for FeMn addition

INPUT
Bath weight, t 190 Amt. of SiMn, kg

OUTPUT SiMn + others (OPTION 1) FeSi + others (OPTION 2)

0.0364 Amt. of FeSi, kg 1137 C-pick-up from FeSi, % 0.0005

Target composition, %

C 0.055

Mn 0.28

Si 0.28 Composition Recovery, % Si, % 15 0.5 0.77 0.3 75.5 C 100 100 100 100 100 Mn 75 95 95 95 75 Si 95 70 70 70 62 Rate, Rs./kg 83 96 160 170 61

3733

C-pick-up from SiMn, %

Amt., kg HC FeMn MC FeMn LC FeMn -1723 -1510 -1501

Total Cost, Rs./t 760 359 288

C-pickup, % -0.0235 0.0252 0.0333 HC FeMn MC FeMn LC FeMn

Amt., kg 789 691 687

Total Cost, Rs./t 763 947 980

C-pick-up, % 0.0274 0.0051 0.0014

Ferro-alloy C, % Ferroalloy details SiMn HC-FeMn MC-FeMn LC-FeMn FeSi 1.85 6.6 1.4 0.39 0.08 Mn, % 60.5 71 81 81.5 0

TechCell/TR/JL/19.08.08

COMPARISON OF CONTRIBUTION FOR NEW / EXISTING GRADES W.R.T. BASE GRADE INPUT
Parameter Average width Average slab thickness Density of steel Average casting speed Total Quantity Cost of production of base grade Grade extra NSR UOM mm mm t/m3 m/min t Rs./t Rs./t Rs./t

OUTPUT
Base grade 1250 69.0 7.8 5.5 1000 28290 0 38990 New grade 1450 69.0 7.8 4.9 1000 28290 5000 45990 Parameter Additional NSR over grade extra Productivity Contribution per hour Total revenue UOM Rs./t t/hr Rs. Lakhs/hr Rs. Lakhs Base grade 0 222.01 23.75 0.00 New grade 2000 229.43 29.14 20.00

TechCell/TR/11.03.08

T Routray/C Mukesh, 21.04.08

TITANIUM ADDITION IN IF STEEL Total Ti / Density Total Ti / Bath % Ti in Ti- Actual % Ti Pure Ti % Ti FeTi %C %N %S weight, wire or of FeTi FeTi wire, reqd. reqd., kg recovery lump, kg reqd., t FeTi lump wire, g/m reqd., m kg reqd. 0.0050 0.0050 0.0080 0.069 170 117 70 168 35 479 464 1033

Enter LF final %C

Enter LF final %N

Enter LF final %S

Enter Liq. Metal weight

Enter % Ti in ferroalloy

Enter % recovery expected

Enter Applicable density of for wire Ti wire in feeding gram only

ALUMINIUM AND OXYGEN ADDITION FOR CHEMICAL HEATING AT VD/VOD Particulars Amount of Al required for 60C temp. rise Oxygen required Total oxygen required Extra oxygen required to be added Oxygen content rise due to extra oxygen added Oxygen content rise due to extra oxygen added UOM kg m3 m3 m3 kg ppm Value 300 300 429 129 184 1080 22.4 litres is equivalent to 32 kg at STP. Assumption Addition of 50 kg Al raises temp. by 10C. 1 kg of Al consumes 1 m3 of oxygen. Assuming 70% recovery of oxygen.

TechCell/TR

Formulae for solubility in austenite

Irvine: log[Nb][C+12/14N] = -6770/T+2.16 Mori: log[Nb][C]0.87= -7700/T+3.18 log[Nb][N]0.65[C]0.24 = -10400/T+4.09 Meyer: log[Nb][C] = -7290/T+3.04 log[Nb][N+C] = -5860/T+1.54 Siciliano:
log [ Nb] [ C  1214 N] ! 2.26  838 [ Mn]0.246  1730 [Si]0.594  6440 T

Example
C Mn Si Nb N 0.04 1.55 0.15 0.1 0.005 T(K)= 1467 1427 1503 1341 1508 1315 1466 I N P U T T(C)= 1194 1154 1230 1068 1235 1042 1193

Dong:
log [ Nb] [C  12 14 N ] ! 3.14  0.35[ Si]  0.91[Mn]  1371[ Mn]  923 [ Si]  8049 T

Irvine NbCN Mori NbC Mori NbCN Meyer NbC Meyer NbCN Siciliano NbCN Dong NbCN

T Routray/J Lal, 18.09.07

Critical temperatures of Grades under Development, based on Empirical Formulae

Aim chemistry, %

Critical Ac1 temp., C

Parameter CR01AC CR02AC IF005C CE01AC WT41BM ST460C PP70BC DP01AC

C 0.007 0.015 0.005 0.008 0.190 0.060 0.055 0.070

Mn 0.070 0.180 0.100 0.300 0.300 1.480 1.630 1.250

Si

S 0.008 0.008 0.008 0.005 0.012 0.008 0.004 0.005

P 0.015 0.020 0.015 0.080 0.018 0.015 0.007 0.008

Al 0.040 0.055 0.040 0.250 0.035 0.035 0.018 0.030

Nb

Cr

Ni

Cu

Ti

Mo

N 0.0045 0.0040 0.0035 0.0020 0.0090 0.0100 0.0060 0.0040

As

Ac1-1 1331 1329 1331 1343 1336 1301 1313 1360

Ac1-2 722 721 722 732 727 711 718 749

Ac1-3 711 709 710 715 712 688 692 717

0.035

0.430 0.250 0.130 0.320 1.250

0.060

0.047 0.063

0.180 0.200

0.006

0.000

T Routray/J Lal, 18.09.07

Critical temper Critical Ac3 temp., C Parameter CR01AC CR02AC IF005C CE01AC WT41BM ST460C PP70BC DP01AC Ac3-1 910 898 911 919 845 840 852 893 Ms-1 495 491 490 493 438 466 464 459

Critical Ms temp., C Irvine NbCN #NUM! #NUM! #NUM! #NUM! #NUM! 1182 1205 #NUM! Siciliano Meyer NbCN NbCN #NUM! #NUM! #NUM! #NUM! #NUM! 996 1089 #NUM! #NUM! #NUM! #NUM! #NUM! #NUM! 1184 1209 #NUM! Mori NbCN #NUM! #NUM! #NUM! #NUM! #NUM! 1210 1205 #NUM! Dong NbCN #NUM! #NUM! #NUM! #NUM! #NUM! 1145 1185 #NUM! Turkdogan NbCN #NUM! #NUM! #NUM! #NUM! #NUM! 1683 1695 #NUM! Meyer NbC #NUM! #NUM! #NUM! #NUM! #NUM! 1031 1052 #NUM! Mori NbC #NUM! #NUM! #NUM! #NUM! #NUM! 1109 1133 #NUM! Turkdogan NbC #NUM! #NUM! #NUM! #NUM! #NUM! 1077 1102 #NUM!

Critical precipitation temperatures in austenite phase, C Turkdogan Turkdogan NbN TiC #NUM! #NUM! #NUM! #NUM! #NUM! 1153 1134 #NUM! #NUM! #NUM! 803 #NUM! #NUM! #NUM! 850 #NUM! Turkdogan TiN #NUM! #NUM! 1423 #NUM! #NUM! #NUM! 1331 #NUM!

Ms-2 534 527 534 526 450 469 464 469

Ms-3 555 548 555 547 461 484 478 483

Ms-4 525 517 525 515 444 443 436 446

Ms-5 533 525 532 523 458 459 448 456

NbC-1 #NUM! #NUM! #NUM! #NUM! #NUM! 1044 1061 #NUM!

NbC-2 #NUM! #NUM! #NUM! #NUM! #NUM! 1135 1161 #NUM!

TiC-1 #NUM! #NUM! 735 #NUM! #NUM! #NUM! 778 #NUM!

TiC-2 #NUM! #NUM! 803 #NUM! #NUM! #NUM! 850 #NUM!

TiCN

TiS #NUM! #NUM! 1307 #NUM! #NUM! #NUM! 1161 #NUM!

T Routray/J Lal, 18.09.07

Critical temper

Parameter CR01AC CR02AC IF005C CE01AC WT41BM ST460C PP70BC DP01AC

Ti(CS) #NUM! #NUM! 1266 #NUM! #NUM! #NUM! 1207 #NUM!

V(CN)

Turkdogan VC #NUM! #NUM! #NUM! #NUM! #NUM! #NUM! 709 #NUM!

Turkdogan VN #NUM! #NUM! #NUM! #NUM! #NUM! #NUM! 949 #NUM!

VN #NUM! #NUM! #NUM! #NUM! #NUM! #NUM! 934 #NUM!

AlN 1145 1171 1113 1290 1221 1236 1082 1094

B4C3

Turkdogan BN #NUM! #NUM! #NUM! #NUM! #NUM! #NUM! #NUM! #NUM!

MnS 1186 1290 1224 1295 1406 1584 1490 1484

Pearlite Pearlite Bainite Bainite Recrystallization incubation completion incubation completion temp., C period, sec period, sec period, sec period, sec

Final grain size, ASTM g.s. no. 8 8 8 8 8 8 8 11

Final grain CE (IIW), for size, Pearlite, % C > 0.12% microns 22.45 22.45 22.45 22.45 22.45 22.45 22.45 7.94 0.019 0.045 0.022 0.058 0.240 0.307 0.375 0.318

T Routray/J Lal, 18.09.07

Critical temper

Flat Rolling Fundamentals by Jinsberg

ISIJ International, Vol. 40 (2000), No. 4, pp. 380385 YS, Mpa low carbon microalloyed steels 94 98 95 138 123 157 178 243

Parameter CR01AC CR02AC IF005C CE01AC WT41BM ST460C PP70BC DP01AC

CE (PCM), for C < 0.12% 0.011 0.024 0.010 0.037 0.213 0.138 0.162 0.184

YS, Mpa

Tensile strength, Mpa

low carbon plain low plain low microalloyed carbon steel carbon steel steels 84 298 276 86 301 317 82 299 293 119 340 331 122 325 681 152 348 704 164 368 796 227 435 716

Particulars ASTM Grain size no. No. of grain per square inch at 100X magnification Average grain area Average grain area Grain diameter

UOM no. no. mm

2

Value 9 256 0.000252016 252.015625 15.88 output output Input

micron micron

Tamanna,1/31/2012

Calculation of time required for casting

parameter weight of steel in ladle density of steel casting speed width thickness time required for casting unit t t/m3 m/min mm mm min value 170 7.8 5 1250 60 58

T.Routray, 15.01.08

Calculation of Length of coil

parameter Total weight of coil Density of steel Thickness of coil Width of coil
Total length of coil

Approximate weight of specimen of same coil

value 22.00 7.8 9.53 1500
197

unit t t/m3 mm mm
m

parameter
Specimen thickness Specimen width Specimen length Specimen weight

unit
mm mm mm kg

value
9.53 50 50 0.19

Theoritical calculation of Aluminium requirement

Phosphorous balance of carry-over slag
% P2O5 in Eaf Slag -> Heat Size Net "P"rev at LF -> "P" reverted into LF L/M from C/O slag P2O5 reverted from LF slag Quantity of carried over slag 0.7 195 0.0005 0.975 2.23 319.0 % T % Kg Kg Kg Tap % C Tap [O] ppm Tap temp C

0.035

772

1620

Log[%C]=f1+[f2/T(inC)]+f3xLog[O,ppm] Where, f1 f2 f3 2.236 -1303 -1

reduction Aluminium balance at primary deoxidation

% FeO in Carry over slag FeO from carry over (C/O) slag % of total FeO (of C/O) reduced during tapping Aluminium required for FeO reduction ( 3FeO+2Al = Fe + Al2O3) Total Aluminium reqd for reduction Dissolved Oxygen, Dissolved Oxygen, Al reqd for De-oxdn, LF in Al(T) Al in Liquid Steel Oxidation loss Oxidation loss Al in Al ingot Total Aluminium reqd during tapping i.e., Specific Al consumption Requrement of Al in Refining process

Aluminium required for P2O5

1.76 Kg 25 79.75 30 5.99 7.76 772 150.54 169.36 0.04 78.00 45.0 204.09 99.00 459.20 2.35 % Kg % Kg Kg ppm Kg Kg % Kg % Kg % Kg kg/t

Oxygen Requirement to achieve target [

Oxygen

Target 800 151.67

Actual from Celox 700 Nm3 / heat

Coke Requirement to achieve target [O]

Oxygen Carbon

Target 800 19500 26.00

Actual from Celox 900 gm/ heat Kg / heat

Elemental %Al Arcing time, mins Vigorous purging time, mins Oxygen introduced due to arcing & purging, ppm % FeO in LF "in" slag % MnO in LF "in" slag Total Al
Total Aluminium reqd during process Total Aluminium reqd during process Al recovery, %

0.045 40 10
115.00

Aluminium,kg 90

5 3

25 1.25 29 145
604.67 3.10 14.79

Total Al wire reqd in Kg Kg / TLS %

455

Steel Chemistry Element % / PPM C 0.055 Si 0.265 S 0.007 P 0.008 Mn 1.590 Al(t) 0.023 Al(s) 0.025 N 72 Ca 32 V 0.059 Nb 0.058 Ni. 0 Cr 0.16 Ti 0.012 Cu 0 CEP LIQUIDUS 0.0656 1521 Td Temp 1566 Lance error 0 0

Caster-1 : Casting Speed Calculator for 60 mm thick Slab Width Super Heat VAG [ Mn > 0.8 ] 4.54 4.64 4.64 <1300 45 4.36 4.46 4.46 >1300 45

VAG [ CEP > 0.07 ] NON VAG [ CEP < 0.07 ]

VAG : Value Added Grade CEP : Carbon Equivalent Potential

1.777777778 38.94 15 17.7

0.5625 14.82

T Routray, 05.10.07

Formula for calculation of Temperature drop during rolling of steel User unit Unit Value 2 5.67E-08 Stefan-Boltzman constant W/m K Emissivity 0.8 Width mm 1250 Thickness mm 4.5 Rolling speed m/s 4.2 Ambient Temperature C 40 Temperature of rolled material C 810 Density of rolled material kg/m3 7800 Specific heat of rolled material J/kgK 500 Parameter Temperature drop per unit time Total temperature drop due to radiation ---------> due to convection -------> MKS unit Unit Value 2 W/m K 5.67E-08 0.8 m 1.25 m 0.0045 m/s 4.2 K 313 K 1083 kg/m3 7800 J/kgK 500 /s /s /s 3.53 0.05 3.58

input by user