Improvements in EAF operation by the use of refining simulation tools and mass-balance programs for foaming slag

摘要

The paper shows how the Refining Simulation and EAF Foamy Mass Balance programs can be applied to actual plant conditions and how this has resulted in significant process improvements over the last few years. The benefits of improved foaming slag conditions in terms of consistency and length of foaming that lead to improved energy efficiency and reduction in refractory and electrode consumption are being proven in more plant applications. In addition, the back calculation of scrap chemistry to better design flux recipes and for compilation of a historical database to enable predictive control of slag compositions, has enormous potential to improve the consistency of foaming in the EAF. The program is being used under license agreement at a number of plants with positive reaction and good early results. The refining simulation has shown the potential for changes to charge design and/or injection parameters that can improve the endpoint control or achieve the same endpoint with lower consumption of oxygen and carbon. The overall effect of process changes on production rate and cost should be carefully considered with the aid of a mass and energy balance.