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Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 1 of 9
Variants of classic ladle furnaces can be combined In order to meet the requirements of steelmaking
with alloying equipment, wire injection facilities as industries, Siemens VAI Fuchs has constructed
well as with porous plug(s) for stirring and homog- roughly 100 RH/RH-TCOB and VD/VD-OB degassers
enization. This enables one unit to produce a wide worldwide since 1978, as shown in Figure 1.
variety of steel grades, which are relatively less re-
Table 2: Typical impurity content, after [3], [4]
stricted in terms of carbon and gas contents.
Steel product Max. impurity (in ppm)
Over the past years, customers continuously Inclusion size, D
increased their requirements on the steel quality, IF steel [C]≤10-30, [N]≤40-50,
which meant fewer impurities, more cleanliness T.O.≤40
(lower inclusion content), more stringent quality Automotive and deep [C]≤30, [N]≤30, D<100µm
drawing
steel (less variation of quality from cast to cast)
Drawn and ironed cans [C]≤30, [N]≤30, T.O.≤20,
and better surface quality as well as homogeneity. D<20µm
Thus steelmakers were forced to equip their steel Alloy steel for pressure [P]≤70
shop with modern secondary metallurgy facilities, vessels
which were able to reduce carbon, sulfur, oxygen, Alloy steel bars [H]≤2, [N]≤10-20, T.O.≤10
hydrogen, and nitrogen contents, as well as non- HIC resistant steel [S]≤10, [P]≤50
Line pipe [S]≤10-30, [N]≤35-50,
metallic inclusions in the steel to those strict
T.O.≤30, D<100µm
content degrees of customer fulfillment.
Sheet for continuous [N]≤30
The existence of these impurity elements annealing
decreases the physical and mechanical properties Plate for welding [H]≤1.5
Ball bearings T.O.≤10, D<15µm
of steel products. Oxygen and sulfur contribute to
Tire cord [H]≤2, [N]≤40, T.O.≤15,
the formation of non-metallic inclusions which af- D<10-20µm
fect the steel cleanliness. One example of the ef- Non-grain-oriented [N]≤30
fort to reduce impurities is summarized in Table 1. magnetic sheet
Heavy plate steel [H]≤2, [N]≤30-40, T.O.≤20
Table 1: Impurity content (in ppm) [2]
Dcluster <200µm, Dsingle
1960 1980 2000 Future inclusion <15µm
T.O. 30 30 10 10 40
H 6 6 1 1
Total 1036 436 121 81 30
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 2 of 9
The RH degasser, Figure 2, is the most widely-used the vessel, as well as of the snorkel and vessel
facility for recirculation degassing processes. In this diameter. The RH degasser can be equipped with a
technique, two snorkels of the vessel are immersed Technometal Combined Oxygen Blowing (T-COB)
in the steel ladle. The pressure inside the vessel is lance for oxygen blowing, vessel preheating,
reduced by a strong pumping system. The steel is chemical heating and skull removal.
encouraged to circulate up one snorkel and down
The RH degasser is mostly used in BOF steel mills
the other, through the injection of argon into the
because of its shorter vacuum treatment time
“up” leg which lowers the apparent density of
allowing rapid decarburization and high-alloy yield
liquid steel.
with narrow tolerances. The installation of a RH
T-COB Lance Vacuum alloying degasser in a BOF steel mill has the following
hopper purposes [5]:
• Production of ULC IF steel grades,
• Reduction of nitrogen content,
Vacuum vessel
• Production of heavy plates with minimum
hydrogen content,
• Increase of alloying output of elements with
high oxygen affinity (e.g. B, Zr, Ti),
Ladle
• Treatment of steel grades with high
Argon tuyeres requirements on cleanliness.
The combination of the RH degasser in a BOF steel
Slide Gate mill is shown in Figure 3:
• BOF – RH – CC
• BOF – CHS – RH – CC
• BOF – LF – RH – CC
BOF
BOF CHS CC
RH
LF
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 3 of 9
lance. The oxygen is blown into the steel to react The routes of VD in BOF steel shops are illustrated
with dissolved aluminum, thus transferring the in Figure 5 as follows:
heat of the reaction into the liquid metal. The • BOF – VD – CC
lance is also used for forced decarburization, vessel
• BOF – CHS – VD – CC
preheating, and skull removal.
• BOF – LF – VD – CC
In the second and third route, the tapping
temperature can be lowered due to the capability
of CHS and LF for heating. It was stated in [6] that
the BOF-LF-RH-CC route is used to produce steel
with high surface quality. To produce ULC with
lower sulphur content, the hot metal must be
desulphurized before BOF treatment.
CHS
In a vacuum tank degassing system (VD/VD-OB),
the ladle is placed into a chamber (tank) which is
then sealed off and evacuated, Figure 4. Inert gas
(argon) is injected through porous plugs integrated
BOF CC
in the ladle bottom in order to provide an effective VD
stirring performance and to expose the steel melt
to vacuum. The tank degasser operates active
slag/metal mixing. Therefore it can effectively be
used for desulphurization by providing the ladle
slag with a high desulphurization capability. The LF
process is also capable of denitrogenation, dehy- Figure 5: VD in BOF steel shop
drogenation and decarburization as well as of
As in the RH route described abbove, the steel is
removing non-metallic inclusions during the
transported to the VD station after tapping from
vacuum treatment. A lower level of nitrogen
BOF. This route can be equipped with trimming or
content can be achieved with a VD plant due to its
bubbling stations. It needs, however, a relatively
capability of desulphurization and maintaining
higher tapping temperature to compensate the
lower oxygen content in the steel melt.
temperature drop during alloying, slag
Bins for alloying
and fluxes
Oxygen and stirring lance
O2 / Ar / N2
conditioning, e.g. for desulphurization and vacuum
Wire injection treatment. The VD plant can be equipped with an
oxygen lance to make the heating of steel possible.
The lance can also be used for forced decarburiza-
Vacuum alloying hopper
Furnace camera tion in the case of a VD-OB plant.
In the second and third route, the tapping
Vacuum pump
temperature of the BOF can be lowered due to the
Ar / N2
capability of CHS and LF for heating.
Slide gate Bottom porous plugs
The vacuum tank degasser is implemented in BOF
Vacuum tank cover steel shops for the following purposes:
• Production of pipeline steel grades, especially
HIC (Hydrogen Induced Cracking) resistant pipe
steels for oil and gas transportation,
• Production of ultra low sulphur content steel
grades,
• Production of ULC IF steel grades,
• Reduction of nitrogen content,
Ladle • Production of heavy plates with minimum
hydrogen content,
Vacuum tank • Production of high strength steels,
• Treatment of steel grades with high
Figure 4: Vacuum tank degasser at HKM requirements on cleanliness.
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 4 of 9
In a VD plant, a wide range of different steel grades others
1% peritectic steel
can be treated as shown in the following section, micro - alloyed 7% carbon steel
8%
taking the Huettenwerke Krupp Mannesmann steel
34%
GmbH (HKM) as an example. unalloyed steel
12%
SECONDARY METALLURGY AT HKM
line pipe- heat treatable
Hüttenwerke Krupp Mannesmann GmbH (HKM) is steels steel
17%
an integrated iron and steel plant consisting of a 21%
and the steel plant. The steel plant itself has a bearing steel
axles and profiles
forging steel 2% boilertube steel
capacity of 6 million t/a crude steel, thereby 2% 5%
4%
producing the input material for the three share conduit pipe steel carbon- and heat
treatable steels
holders, ThyssenKrupp Steel AG (50%), 26%
6%
Mannesmannröhrenwerke AG (30%), and steel for wheel rims
Vallourec Mannesmann Tubes (20%) [7]. oilfield tube- and 6%
gas bottle steel
The product range consists of slabs for heavy 18% high strength,
constructual steel alloyed fine grained
plates and hot strip mills, as well as of round steels
18%
strands for e.g. seamless tubes and forging prod- 13%
ucts. Details of the product mix and its production b. Round strands (21% share on total production)
shares are shown in Figure 6. Figure 6: Product mix at HKM
alloys + fluxes
HM-desulfurisation CaSi CaSi
HM mixers O2
alloys
BOF 2 sublance dart
CaC2 + Mg
Ar
N2
Alloys +
Ar
fluxes N2 / Ar N2 / Ar
VD 3 VD 4
N2 alloys + fluxes
CaC2 + Mg Ar Ar
N2 / Ar CaSi Ar
rail transport Tap Ar Bubbling 2
O2
N2 alloys
BOF 1 sublance dart Ar
reladle station N2 / Ar
N2
Ar
Alloys + Ar Bubbling 3
1
fluxes
2 alloys + fluxes
3 CaSi Ar Ar CaSi
rail transport charging boxes Ar Ar
N2 / Ar
Tap Ar Bubbling 1
N2 / Ar N2 / Ar
VD 1 VD 2
change vessel
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 5 of 9
The hot metal is transported with 100 t ladles by the installation of the second VD plant and twin
either to hot metal mixers or to the reladling VD plant in 1990 and 1998, respectively. As shown
station to prepare the charging material for the in Figure 9, the amount of vacuum treated steel
treatment in the steel plant. Depending on the increased from 34.7% in 1996 to more than 50% in
requirements on the steel composition, the hot 2005.
metal can be pretreated in two desulphurization 6
stations before charging into the BOF.
5
The scrap is sorted, prepared and charged to the
BOF converter as cooling material. The hot metal 4 Total Steelproduction
Mio t/a
and scrap is blown with oxygen and mixed by 3 54.1%
bottom inert gas stirring. During tapping, the
converter slag carry -over is minimized by the 2
34.7%
application of a dart and an infrared camera. A Vacuumtreated Steelproduction
1
minimum slag carry-over is essential for proper
ladle treatment in secondary metallurgy. The main 0
alloying and fluxes are added. The steel is then 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
Ar
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 6 of 9
alloys
+
f luxes
dart
alloys CaSi
Ar
N2 Ar
alloys
Ar +
f luxes
Ar
120 100
90
Cumulative frequency, %
100
80
Number of heats, n
70
80
60
60 50
40
40
30
20
20
10
0 0
Figure 14: Offgas composition, pressure and argon
5 10 15 20 25 30 35 40 45 50 55 60 flow rate during HIC resistant
Carbon content, ppm production in VD
Figure 12: The distribution of carbon content after The sulphur content at the end of vacuum
vacuum treatment treatment is shown in Figure 15. A sulphur
content of 4 ppm can be achieved after vacuum
PRODUCTION OF HIC RESISTANT STEELS treatment.
Figure 13 shows the route for HIC resistant steel 400 100
Cumulative frequency, %
90
production. Before the BOF process, the hot metal
350
80
Number of heats, n
300
is desulphurized at the hot metal desulphurization 70
250 60
station by the injection of magnesium and CaO. At 200 50
the BOF, only scrap with low sulphur contents 150 40
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 7 of 9
THE HEATING SYSTEM The thermal energy in the melt is generated by the
reaction of oxygen with the dissolved aluminum in
In 2004, Siemens VAI Fuchs supplied HKM with
the liquid steel. The oxygen is blown by a water-
two water-cooled oxygen blowing lances for
cooled top lance with a nozzle diameter of 31 mm
chemical heating on the tank cover No. 03 and 04,
onto the surface of the steel melt. The lance is
see Figure 16. In 2005, 1.8% of the production
positioned at a distance of 900 mm above the
was reheated by using this system. This equates to
surface during the blowing cycle. The oxygen
approximately one melt per calendar day. The
blowing rate is 40 Nm3/min.
chemical heating system is not used to reduce the
tapping temperature, but solely for the correction Figure 17 shows the correlation between the
of unscheduled temperature losses resulting from increase of steel temperature and the amount of
operational disturbances [7]. injected oxygen.
100
swivel drive lift drive
lance carriage
suppy of O2 60
and water
lift pillar 40
oxygen lance
trestle
20
0
0 200 400 600 800
3
Amount of injected oxygen (m )
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 8 of 9
Based on the many years of experience with REFERENCES
operating VD plants at HKM, the advantages and
[1] Östberg, G.: Modernizing steelmaking. A
disadvantages of VD degasser are given as follows:
reappraisal of the Perrin process. Part I. La
Advantages Revue de Métallurgie-CIT. January. 2001. pp.
• The installation of a VD plant in a steelwork 41/53
provides a high production flexibility of steel [2] Bannenberg, N.: Sekundärmetallurgie bei der
grades (product mix) Dillinger Hütte, Gestern-Heute-Morgen.
Aachener Stahlkolloquium. 2000. pp.179/188
• High applicability for desulphurization, good
degassing (de-N and de-H) and decarburization [3] Zhang, L.; Thomas, B.G.: State of the art in
performance evaluation and control of steel cleanliness, ISIJ
International. Vol. 43. No. 3. 2003. pp.
• The VD operation has a positive effect on the
271/291
steel cleanliness
[4] Cramb, A.W.: Secondary steelmaking and
• The degasser can be integrated with chemical casting: the basis for control of steel
heating technology in a compact plant properties and quality. SJM. 1997. 26. pp.2/7
Disadvantages [5] Jungreithmeier, A.; Reisinger, P.; Jandl, K.;
• Stringent stirring availability of porous plugs Viertauer, A.; Pissenberger, E.: Vacuum
degassing at voestalpine Stahl. BHM. Heft 5.
• Risk of carbon pick up during ULC steel
2002. pp.138/144
production
[6] Jungreithmeier, A.; Pissenberger, E.;
• Longer treatment time of ULC production Burgstaller, K.; Mörtl, J.: Production of ULC IF
steel grades at Voest-Alpine Stahl GmbH. Iron
SUMMARY and Steel Technology, April 2004. pp.41/48
The secondary metallurgical equipment, especially [7] Schlüter, J.; Koschinski, A.; Klärner, A.; Arnold,
the vacuum degasser, are widely used to produce H.: Effect of VD-OB technology on product
high quality steel. The application of a VD plant in quality, 5th European Oxygen Steelmaking
a BOF steel mill provides high flexibility for pro- Conference, Aachen, 26-28 June 2006, pp.
ducing various steel grades. The installation of 375/381
oxygen blowing in a VD plant provides the possi-
bility of adjusting the unscheduled temperature
losses that result from operational disturbances.
CURRICULUM VITAE
Mr. Holger Arnold is currently working for Hüttenwerke Krupp Mannesmann
GmbH and is married to Dr. Heike Deneke-Arnold.
Between 1990 and 1997, Mr. Holger Arnold studied Metallurgical and Materials
Engineering at the Rheinisch-Westfälischen Technical College in Aachen where he
focused on Metallurgy.
He began his career as a plant engineer for steelmaking process technologies at
the steel plant of Krupp Mannesmann GmbH in Duisberg Huckingen in 1997.
In the year 2000, he moved on to become plant engineer at the treatment facility
and in 2002 was promoted to plant superintendent. As of January 2006, Mr.
Arnold is the process manager of secondary metallurgy.
During his employment with Krupp Mannesmann GmbH, he held several
speeches around the world and has published two articles.
Some of these dealt with monolithic lining systems; treatment of ULC, IF steels
and line pipe steels in tank degassers; steel treatment in vacuum metallurgy;
steel treatment in VD plants, VD-OB technologies, integration operative
disposition systems and aluminum-killed steels.
Linz/Austria, October 2006 Secondary Steelmaking Session – Paper No. 7.3 / Page 9 of 9