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High Efficiency Dephosphorization by Mixed Injection


during Steelmaking Process
Ming Lv,* Rong Zhu, and Ling-zhi Yang*

Research on dephosphorization has


A new dephosphorization technology with introduction of partial CO2 into been carried out by many researchers.
O2 is proposed in this paper. Thermodynamic characteristics and dephospho- Ogawa et al. reported that hot metal was
rization mechanism by introduction of CO2 are analyzed and the results dephosphorized and decarburized contin-
uously in the same basic oxygen furnace,
show that using CO2 as partial dephosphorization oxidant can change the
with intermediate deslagging and reusing
selective oxidation condition of steelmaking system, control the temperature slag after decarburization so as to realize a
of bath, strengthen the stirring ability, and finally obtain a high efficiency of high dephosphorization rate and minimize
dephosphorization. Meanwhile, the relationship between selective oxidation the quantity of slag.[2] Tian et al. adopted
temperature T of C and P, partial pressure of CO gas, slag activity, and double-slag operation for dephosphoriza-
0 0:0401 tion in a 210 t converter to produce low
compositions of melt is obtained as follows. T ¼ ðPaCO0:0080=P Þ
 phosphorus steel, and a phosphorus con-
4CaOP2 O5
tent of less than 0.005% was obtained in
expð0:0403½%C  0:0030½%Si þ 0:0011½%Mn þ 0:3515½%P þ 7:3986Þ Fur-
their trails.[3] Some researchers developed
thermore, dephosphorization trails are carried out in a 30t steelmaking the hot metal pretreatment for dephospho-
converter and a 300t special dephosphorization converter, respectively. It is rization in a special dephosphorization
concluded that the new technology of injecting CO2–O2 mixture is beneficial vessel, which improved the thermody-
to reduce phosphorus content in liquid steel, increase the partition ratio of namic and kinetic conditions of dephos-
phosphorus, and reduce iron loss of slag. phorization, hence increased the
dephosphorization rate.[4–10] Zeng et al.
studied the composite dephosphorization
agent which promoted the foaming slag in
1. Introduction dephosphorization process.[11] In this case, the dephosphoriza-
tion reaction in the interface of steel and slag was promoted.
Dephosphorization, one of the most important tasks during Basu et al. investigated the change of dephosphorization
steelmaking process, is mainly achieved at low temperature in the capability during different smelting stages, and found that the
early stage of smelting process. Unfortunately, heat generated by phosphorus partition ratio remained closer to equilibrium
oxidation reactions will quickly increase the temperature of liquid during the early stage but gradually decreased.[12,13] It decreased
metal. Meanwhile, in the early stage of smelting process, the from a mean value of around 60% at 5 min to approximately 40%
decarburization reaction is limited because of the low temperature, after 15 min of blow. Although so much research about
so large amount of CO gas has not been generated, which will dephosphorization has been made in the previous work, there
result in poor dynamic stirring condition. The conditions is no detailed research about dephosphorization by mixed
mentioned above are not good for dephosphorization.[1] Therefore, injection of CO2 and O2 in steelmaking process.
realizing high efficiency of dephosphorization has always been one The research on CO2 being a resource utilized in steelmaking
of the technical difficulties in steelmaking process. process has carried out for a long time. Mannion et al.
expounded the principle of decarburization by CO2, and found
Dr. M. Lv that part of CO2 could participate in steelmaking reaction and
School of Metallurgical Engineering enhance the stirring ability.[14,15] Seetharaman and Wang used
Xi’an University of Architecture and Technology CO2 in stainless steel refining process to replace part of Ar
Xi’an 710055, P. R. China and O2, to realize Cr retention as well as decarburization.[16,17]
E-mail: lvmingsteel@163.com
Du et al. analyzed heating effect and mixing ability of CO2 used
Dr. L. Z. Yang in vanadium extraction process, and proved that CO2 and O2
School of Minerals Processing and Bioengineering
Central South University mixed blowing was effective.[18] Moreover, Yi et al. introduced
Changsha 410083, P. R. China CO 2 into O2 injection by top lance during BOF steelmaking
E-mail: yanglingzhi@csu.edu.cn process, which decreased the temperature of hot spot and
Prof. R. Zhu reduced the dust generation.[19,20] But the effect of CO2
School of Metallurgical and Ecological Engineering introduction on dephosphorization has not been focused.
University of Science and Technology Beijing On the basis of former work, a new dephosphorization
Beijing 100083, P. R. China
technology by injecting CO2–O2 gas mixture in a converter was
DOI: 10.1002/srin.201800454 proposed. Thermodynamic characteristics and dephosphorization

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mechanism of the new process were analyzed firstly. Then the  


industrial experiments on dephosphorization by introducing CO2 PCO =P0  a0:2
4CaOP2 O5
were carried out in a 30t steelmaking converter and a 300t special ΔG2 ¼ ΔG02 þ RTln 0:4
ð4Þ
ðPCO2 =P0 Þ  f 0:4
P  ½%P  a0:8
CaO
dephosphorization converter, respectively. This research will
provide foundation for dephosphorization by using CO2–O2
mixtures. where, ΔG01 ¼137 890–126.52T J  mol1, ΔG02 ¼–144
446 þ 43.22T J mol1.
Supposing aCaO ¼ 1 due to solid CaO added into molten
2. Analysis of Dephosphorization Mechanism bath. When ΔG1 equals to ΔG2 , T is the transformation
temperature of selective oxidation of C and P. If the bath
2.1. Analysis of Selective Oxidation Mechanism temperature is lower than T, reaction (2) will occur in prior to
reaction (1), phosphorus will be oxidized more easily than
CO2 is a weak oxidation gas at steelmaking temperature, the carbon, and vice versa.
relation of 4G0-T for different elements oxidized by CO2 is The relationship between PCO =P0 and T, f C , f P , [%C], [%P],
shown in Figure 1. 4G0 represents standard Gibbs free energy, T a4CaOP2 O5 is expressed in Equation (5).
is the temperature of molten bath.
Figure 1 shows that CO2 can react with C, Fe, Si, and Mn at the f C  ½%C  a0:2
 eð20:42 T Þ
4CaOP2 O5 33959:11
steelmaking temperature. Moreover, CO2 can also dephospho- PCO =P0 ¼  0:4 ð5Þ
rize if CaO is added properly. Hence, C, P, Mn could be oxidized f p  ½%P
selectively by CO2 in the dephosphorization process.
A certain proportion of CO2 will lead to the change of where, PCO =P0 , Partial pressure of CO; T, Bath temperature, K;
oxidation in steelmaking system, which affects the oxidation f C , Activity coefficient of carbon; f P , Activity coefficient of
reaction order of molten pool elements. The reactions of phosphorus; [%C], Mass fraction of carbon; [%P], Mass fraction
decarburization and dephosphorization by CO2 in steelmaking of phosphorus; a4CaP2 O5 : Activity of 4CaO  P2O5.
process are illustrated in Equation (1) and (2), respectively. Based on the Wagner model, activity coefficient of C and P can
be calculated by Equation (6) and (7), respectively.
CO2 ðGÞ þ ½C ¼ 2COðGÞ ð1Þ
logf C ¼ eCC ½%C þ eSi
C ½%Si þ eC ½%Mn þ eC ½%P
Mn P
ð6Þ

CO2 ðGÞ þ 2=5½P þ 4=5ðCaOÞ


¼ 1=5ð4CaO  P2 O5 Þ þ COðGÞ ð2Þ logf P ¼ eCP ½%C þ eSi
P ½%Si þ eP ½%Mn þ eP ½%P ð7Þ
Mn P

Gibbs free energy of the above reactions are shown in The values of interaction parameters are listed in Table 1.[21]
Equation (3) and (4), respectively. From Equation (3) and (4), it can be known that ΔG1 , Gibbs
 2 free energy of the reaction between CO 2 and C is related to
PCO =P0 the square of PCO =P0 , while, ΔG2 is related to PCO =P0 . Both
ΔG1 ¼ ΔG01 þ RTln ð3Þ
ðPCO2 =P0 Þ  f C  ½%C ΔG1 and ΔG2 will increase with the increase of PCO =P0 . The
increment of ΔG1 is greater than that of ΔG2 , so the rise of
CO partial pressure is beneficial for dephosphorization as
well as C retention. When CO partial pressure increases to a
certain value, the selective oxidation order of C and P will be
changed.
Transformation temperature T of selective oxidation of C
and P can be concluded by nonlinear fitting method in
Equation (8).
 0:0401
PCO =P0
T¼  expð0:0403½%C  0:0030½%Si
a0:0080
4CaOP2 O5
þ 0:0011½%Mn þ 0:3515½%P þ 7:3986Þ ð8Þ

Table 1. The values of interaction parameters.

ji C Si Mn P
C 0.14 0.08 0.012 0.051
Figure 1. 4G0-T relation of the reactions between CO2 and elements of
P 0.13 0.12 0 0.062
liquid steel.

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Table 2. The chemical reaction heat and physical absorption heat of CO2 and O2.

Chemical reaction Heat change [Jmol1]


CO2
CO2 þ [C] ¼ 2CO 165 896 – 11.75T – 6.36  104T2 – 3.92  106T1
1/2CO2 þ [Si] ¼ SiO2 þ 1/2CO 417 433 þ 11.75T þ 1.22  103T2 þ 2.31  106T1
CO2 þ [Mn] ¼ MnO þ CO 104 629 – 15.31T þ 1.59  103T2 þ 2.31  106T1
CO2 þ Fe ¼ FeO þ CO 24 137 þ 11.46T–2.47  103T28.08  105T1
O2
1/2O2 þ [C] ¼ CO 108 411 – 4.31T – 5.606  103T2 – 6.575  105T–1
O2 þ [C] ¼ CO2 394 059 þ 5.06T – 4.182  103T2 þ 0.67  105T1
O2 þ [Si] ¼ SiO2 876 097 þ 6.13T þ 0.998  103T2–5.21  105T1
1/2O2 þ [Mn] ¼ MnO 387 277 þ 7.65T – 4.056  103T2 þ 1.275  105T1
1/2O2 þ Fe ¼ FeO 277 522 þ 18.33T – 9.24  103T2 þ 2.474  105T2
Physical absorption heat
CO2 16 421 þ 44.14T þ 4.52  103T2 þ 8.54  105T1
O2 9674 þ 29.96T þ 2.092  103T2 þ 1.67  105T1

2.2. Analysis of Heat Change be decreased. In consequence, CO2 can be used in BOF as
dephosphorization oxidant with the aim to change the selective
Chemical heat generated by the reactions that take place between oxidation condition of steelmaking system, control the tempera-
the elements in the bath and CO2 or O2 can be calculated ture of molten bath, strengthen stirring ability and finally realize
according to Equation (9). high efficiency of dephosphorization.
Z T
ΔHT ¼ ΔH298 þ ΔCP dT ð9Þ 2.3. Analysis of Dephosphorization Kinetics
298

where, T, Bath temperature, K; 4HT, Chemical heat generated by Dephosphorization reaction rate is controlled by mass transfer
the reaction at temperature T, J mol1; 4H298, Chemical heat both in metal and slag phase. In reality, kinetic condition would
generated by the reaction at 298 K, J  mol1; CP, Heat capacity at limit the improvement of phosphorus partition ratio in
constant pressure, J mol1 K1. commercial steelmaking process.[13] Through S. Muka’s test
The chemical reaction heat and physical absorption heat are and model calculation, stirring energy will multiply with the
shown in Table 2. increase of the rate of oxygen supply, which is an effective
It is seen from Table 2, the reactions between CO2 and C or Fe are measure to promote the dephosphorization reaction.[1]
endothermic. While the reactions between CO2 and Si or Mn are Different from O2, all the oxidation reactions between CO2
exothermic, which generates only 30–50% of heat emitted by the and Fe, Si, Mn, P will generate CO gas, while the reaction
reactions between O2 and the same elements. Physical absorption between CO2 and C can increase CO gas volume.[16,22,23] When
heat of blowing O2 is about 64% of that of CO2. Therefore, CO2 is blown into the molten bath at a certain speed, the kinetic
comprehensive cooling ability of CO2 is stronger than that of O2. energy of CO2 is changed to string energy. Then CO2 is heated to
In dephosphorization process, compared with pure O2 the steel temperature and expands. At the same time, CO2 reacts
injection, injection of O2–CO2 mixture can change the selective with C, P, Si, Mn, and Fe simultaneously to produce
oxidation condition of steelmaking system. With the increase of corresponding oxides and CO. The bubbles flotation from CO
reaction proportion of CO2, the temperature of molten bath will and unreacted CO2 drives the flow of molten bath.

Table 3. Gas supply scheme in a 30t steelmaking converter.

Gas flow [Nm3 h1]


Process Blowing position Gas 0–3 min 3–6 min 6–9 min 9 min-end
Conventional process Top blowing O2 8200 7800 7600 8000
Bottom blowing N2-Ar 120 80 120 160
New process Top blowing O2 7800 7400 7600 8000
CO2 800 800 0 0
Bottom blowing N2-Ar 120 80 120 160

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Table 4. Distribution of phosphorus content at the end of dephosphorization period.

Phosphorus content [%]


Items 0.050 0.040–0.049 0.030–0.039 0.020–0.029 <0.020 Heat numbers
Conventional process 62.5% 37.5% 0 0 0 8
New process 0 25% 66.7% 8.3% 0 12

The stirring energy denoted as ECO2 (W) of blowing CO2 in heat and physical heat of introduction of CO2 will control the
converter steelmaking process will be remarkably improved, temperature of molten bath at reasonable level, which will
including the following aspects: 1) The initial kinetic energy improve the stability of dephosphorization.
expressed by Wi of blowing CO2 by the nozzle exit; 2) The Dephosphorization effect can be improved by the new
thermal expansion energy denoted as Wt of CO2 heated from technology resulting from the following three reasons. 1)
room temperature to molten steel temperature. 3) The volume Compared with O2, heat absorption of CO2 (seen in Table 2) will
expansion energy denoted as WCO generated by CO gas from the effectively control the temperature of molten bath at the
reactions. 4) The energy denoted as Wb done by buoyancy of dephosphorization period, which can provide a good thermody-
mixed gas of CO2 and CO. namic condition for dephosphorization. 2) All the oxidation
As a result, blowing CO2 has a stronger ability to stir the bath reactions of CO2 will generate CO gas, at the same time, which
than O2. It is helpful to increase the reaction interface of steel- can strengthen stirring energy remarkably. Hence the dynamics
slag and beneficial for mass transfer and heat transfer, which will of interface reaction between steel and slag is improved, which is
create a good dynamic condition for the dephosphorization beneficial for mass and heat transfer in the process of
reaction. dephosphorization reaction. 3) The effect of controlling
temperature of CO2 extends dephosphorization time, which
can fully complete dephosphorization reaction at the early stage
3. Dephosphorization Experiment in a 30t of smelting process.
Steelmaking Converter
Based on above analysis, the dephosphorization experiment has 3.2. Analysis of Slag
been performed in a 30t converter in Fujian Sanming Iron and
Steel Co., Ltd. The experimental gas supply scheme was shown 3.2.1. Slag Composition
in Table 3. The conventional process uses O2 as top gas and N2–
Ar as bottom gas in the smelting process, while, the new process The viscosity of steelmaking slag decreases with the increase of
blows O2 and CO2 by top lance during the dephosphorization FeO content. FeO content and slag basicity have significant
period of smelting process, and blows N2–Ar at the bottom of the effects on increasing slag viscosity, which is not favorable to
converter during the whole smelting process. dephosphorization. However, reducing FeO content of slag can
improve the yield of metal.[24] Slag composition and partition
ratio of phosphorus obtained from the industrial trails are shown
3.1. Phosphorus Content of Liquid Metal at the End of in Table 5.
Dephosphorization Period

The phosphorus content in liquid steel at the end of


dephosphorization period is listed in Table 4. In the conventional
process, phosphorus content is above 0.040% and the average
phosphorus content is 0.051%. While, through the new process,
phosphorus content in liquid steel is below 0.050% at the end of
dephosphorization period. 75% of the total heats could realize
the phosphorus content lowering 0.040%, and the average
phosphorus content is 0.037%. The average phosphorus content
is reduced by 27.45%.
Figure 2 shows the effect of bath temperature on phosphorus
content at the end of dephosphorization period. It is found that
phosphorus content in liquid steel is low when the temperature
of molten bath is at 1330–1340  C, and phosphorus content rises
with the increase of the temperature. Although low temperature
is beneficial for dephosphorization, when the temperature is
below 1325  C, it is not conducive to melt slag at the
dephosphorization stage, resulting in high slag viscosity, poor
liquidity, and bad dephosphorization effect. By adopting new Figure 2. The effect of bath temperature on phosphorus content at the
technology in smelting process, heat change due to chemical end of dephosphorization period.

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Table 5. Slag composition and partition ratio of phosphorus.

Slag composition [%]


Process CaO SiO2 TFe P2O5 FeO Slag basicity Phosphorus content [%] Partition ratio of phosphorus
Conventional process 33.31 21.36 20.86 2.48 26.71 1.56 0.051 49.51
New process 34.15 20.79 19.89 2.77 25.46 1.65 0.037 74.87

It is found that, in the new process, the total iron content in dephosphorization as well. Therefore, P2O5 content in slag is
slag is slightly decreased from 20.86% to 19.89%, and FeO increased and phosphorus content in liquid steel is reduced,
content is also reduced from 26.71% to 25.46%. CO2 can take which can significantly improve the partition ratio of
part in oxidation reaction instead of O2, so as to enhance the phosphorus.
stirring of molten bath, increase the interface of reaction As shown in Table 5, when adpoting the conventional
between steel and slag, and promote the reactions, which helps smelting process, the partition ratio of phosphorus LP in
to reduce iron loss in slag. dephosphorization slag remains in the range of 40–60, and the
The slag basicity is low at the end of dephosphorization average value is only 49.51. While LP obtained in the new process
period. The slag basicity are 1.56 in the conventional process and is increased to 74.87, indicating the new technology has higher
1.65 in the new process, respectively, which is mainly because at partition ratio of phosphorus and better dephosphorization
the early stage of smelting process, lime and other slagging results. If the basicity of dephosphorization slag can be increased
materials are not melted completely through a short blowing to above 1.8 by adjusting the height of oxygen lance and slag
time and low temperature. system, CO2 will create better conditions for high efficiency
dephosphorization, including the advantages of low temperature
and strong stirring ability during the early stage of smelting
3.2.2. The Partition Ratio of Phosphorus process.

The partition ratio of phosphorus between slag and steel is an


index of the phosphorus holding capacity of the slag, which 4. Dephosphorization Experiment in a 300t
determines the phosphorus content achievable in the finished Special Dephosphorization Converter
steel.[12] In conventional converter smelting process, phospho-
rus partition ratio during steelmaking in commercial BOF Preliminary experimental result in the 30t steelmaking converter
typically remains in the range of 40–60% of the equilibrium has proven the good dephosphorization effect. For further
value due to the limit of kinetic conditions, which indicates that verification of dephosphorization effect, CO2 was injected into a
the end-point slag still has the high ability of dephosphoriza- 300t special dephosphorization converter of duplex steelmaking
tion.[13] So that improving stirring ability will increase the process in Shougang Jingtang Iron and Steel Co., Ltd. Gas supply
partition ratio of P to a near equilibrium value, which will be scheme is shown in Table 6. New process is blowing O2 and CO2
beneficial for dephosphorization. by the top lance of the dephosphorization converter, and blowing
The phosphorus partition ratio is expressed as LP ¼ (%P2O5)/ pure CO2 through bottom blown nozzles of the converter during
[%P], where (%P2O5) and [%P] stand for the mass fraction of the whole dephosphorization process. Experimental data of 380
phosphorus in slag and steel, respectively. It depends mainly on
slag composition and temperature.
Molten bath temperature in the new process is slightly lower
than that in conventional process. Moreover, the stirring ability is
enhanced, which is conducive to good liquidity and high basicity
slag for high efficiency of dephosphorization. More CO gas
generated by injecting CO2 facilitate slag foaming and emulsion,
so the rate of surface renewal is increased, which is beneficial for

Table 6. Gas supply scheme in a 300t dephosphorization converter.

Gas flow [Nm3h1]


Process Blowing position Gas 0–3 min 3 min-end
Conventional process Top blowing O2 35 000–40 000 24 000–25 000
Bottom blowing N2 800 3000
New process Top blowing O2 30 000–35 000 20 000–24 000
CO2 4000–7000 2400–6000
Figure 3. End-point compositions of molten steel in a 300t dephospho-
Bottom blowing CO2 800 3000
rization converter.

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Table 7. Analysis of slag composition in a 300t dephosphorization converter.

Slag composition [%]


Process Heat numbers CaO SiO2 MgO P2O5 MnO FeO TFe Slag basicity Partition ratio of phosphorus
Conventional process 47 29.28 14.72 5.48 6.75 9.51 23.14 18.00 2.00 132
New process 34 29.11 14.65 5.34 7.25 10.26 22.33 17.36 2.01 164

heats were obtained, including 107 heats from the new process, dephosphorization converter is mainly controlled by the added
and 273 heats from the conventional process at the same amount of slagging agent. Therefore, added CO2 has almost no
production period. effect on slag basicity in 300t dephosphorization converter.
Compared with the conventional process, P2O5 content in slag
is increased by 0.5% with adopting the new process. Combined
4.1. Content of Molten Steel in a 300t Dephosphorization with the analysis of the partition ratio of phosphorus LP, it is
Converter found that LP is increased from 132 to 164, indicating that
dephosphorization abiltiy is improved by about 24.2% through
Figure 3 shows the end-point compositions of molten steel by the new process. The results obtained from the 300t converter
two kinds of processes in a 300t dephosphorization converter. experiment are consistent with the results obtained in the 30t
1.73 Nm3 CO2 was consumed per ton steel during the steelmaking converter.
experimental process. In order to ensure proper molten bath
temperature, the amount of coolant was slightly reduced in the
new process, but the same tapping temperature of 1323  C were 5. Conclusion
obtained by both processes.
In dephosphorization converter, the oxidation reaction of Based on the theoretical analysis and dephosphorization
carbon is restricted due to poor thermodynamic condition at low experiments, the following conclusions can be obtained.
temperature of molten bath. However, a small amount of carbon
will be oxidized along with the oxidation of Si, Mn, and P . Partial 1) A new dephosphorization technology which uses CO2
CO2 introduction into O2, can oxidize few carbon by the reaction instead of partial O2 was proposed in this paper. CO2 used
of C–CO2 at dephosphorization temperature. Compared with the as dephosphorization oxidant can change the selective
conventional process, end-point carbon content is increased oxidation condition of steelmaking system, control the
from 3.19% to 3.26% by the new process of blowing CO2–O2 temperature of bath, strengthen the stirring ability and
mixture, indicating that blowing CO2 can inhibit the oxidation finally realize high efficiency of dephosphorization.
loss of carbon during dephosphorization process. Carbon in 2) Selective oxidation temperature of carbon and phosphorus
molten bath is the most important heating element in the was analyzed under the condition of injecting CO2, and the
following decarburization converter, so the decrease of carbon relationship between selective oxidation temperature T,
oxidation can save more chemical heat and reduce the partial pressure of CO gas, slag activity and compositions
consumption of ferrosilicon alloy for decarburization converter. of melt was obtained as follows.
End-point phosphorus content is decreased from conventional ðPCO =P0 Þ
0:0401

0.051% to current 0.044%, indicating that blowing CO2 can T¼  expð0:0403½%C  0:0030½%Si
obtain a better dephosphorization effect compared with the a0:0080
4CaOP2 O5

conventional process. þ0:0011½%Mn þ 0:3515½%P þ 7:3986Þ

4.2. Analysis of Slag 3) Dephosphorization experiments were carried out in a 30t


steelmaking converter and a 300t special dephosphorization
Slag samples in the experimental process were analyzed, including converter, respectively. The results obtained from both two
34 heats obtained by the new process, and 47 heats recevied by the experiments showed that the new technology of injecting
conventional process at the same production period. The average mixed gas of CO2 and O2 is beneficial to reduce phosphorus
value in Table 7 shows TFe content of slag is slightly reduced from content in liquid steel, increase the partition ratio of
18.00% to 17.36% in the new process. TFe content of slag is mainly phosphorus and lower iron loss of slag.
influenced by kinetic condition. Double volume of CO is generated
by the reaction between CO2 and carbon, and all the oxidation
reactions between CO2 and other elements will generate CO gas.
Therefore, the stirring ability of molten bath can be strengthened Acknowledgement
by growing up of a large number of CO bubbles and buoyancy from
The authors thanked the National Natural Science Foundation of China
the inside of molten bath. (No. 51604210), Postdoctoral Science Foundation of China (No.
Slag basicity of the slag are 2.0 in the conventional process and 2018M633477), and Shaanxi Province National Natural Science Founda-
2.01 in the new process, respectively. Slag basicity in tion of China (No. 2016JQ5042) for the financial support of this research.

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