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Chapter Fifteen

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BOF Control

by'J.H. Cox and R.K. Iyengar

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Contents

1

Introduction 970
Background 973
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End Point Control Methods '_. 982
.... Static Models 983 .. ,-
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....... Gas Analysis and Dynamjc Control 992

Sensor Lance Control 1000
Blowing Control Methods .. 1007
Conclusions ........ ... \Is: ... 1011
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I

INTRODUCTION

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As the BOF converter replaced the Open Hearth in North America, more and more emphasis was placed on productivity and control of the process. The steelmaking capacity of one shop, (sometimes a whole plant), was dependent on one or two converters

where previously the load may have been spread over ten or fifteen Open Hearths. Much attention and-effort was directed on the process to ensure that the BOF ran as continuously and

quickly as possible and soon several approaches to process control,

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both new developments and carryovers from bottom blown converter

practices ;-- were in use in the BOF.

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The objectives of any complete process control scheme are the determination of the correct weights of hot metal (liquid iron), scrap, iron ore or mill scale, burnt lime, dolomite, and fluorspar to charge into the vessel, and the amount of .oxygen to

blow, in order to meet the temperature and chemistry aims of a given weight of product with both a minimum of reblown and/or cooled heats and a maximum yield. In many instances blowing control is utilized in an attempt to increase the reproducibility of the slagmaking reactions and to decrease the amount of slopping and yield loss through ejections from the furnace. The practice used to achieve these aims should be the optimum with respect to the minimization of the cost of charge materials and should be

consistent with good metallurgical quality in the ingot or strand cast product.

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The number of items to be controlled and the metallurgical requirements that influence or limit the control methods chosen do vary significantly from plant to plant. Generally the BOF converter is used to produce a given weight and composition of

bloWn metal which, through the addition of ferroalloys in the steel ladle, can produce a product of a required weight, temperature, and

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composl..t~on.

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The three primary elements to be controlled through furnace

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practice are carbon, phosphorus and ·sulfur. The carbon content

is the most important ~~d_is_the primary objective of most control schemes. The sulfur and phosphorus contents are the next items of concern; their relative importance depends on the hot metal composition and products that are to be made. Generally sulfur is of primary importance in a low phosphorus (basic iron) ~ot metal practice and phosphorus is of primary importance in a high phosphorus (Thomas iron) practice.

· End point temperature is one of the critical items in steelmaking as it signifi'cantly affects product quality if the steel is either too hot or too cold. Optimum steel quality for a given grade is achieved only within a very narrow 'range of furnace and ladle temperatures.

In order to minimize material consumption, increase yield, and ensure the required ladle composition, blown metal weight must be controlled so that the correct weight of steel is tapped into the ladle.

In any control scheme, the items discussed are both interrelated and affected by different factors. The end point carbon content is affected by the amount of:

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Carbon in the furnace charge

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Gaseous oxygen blown into the-furnace

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Oxygen contributed by charge iron ore and mill scale, residual furnace slag, and, possibly, air aspiration into the furnace along the oxygen lance

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Oxygen used for combustion of carbon monoxide to carbon dioxide inside the furnace and for fume and slag making reactions through oxidation of iron and metalloids present in the hot

metal.

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The end poi~~ phosphorous content is affected by:

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The phosphorous content of the charge

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Iron oxide content of the slag

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Whether the slag is saturated with respect to CaO

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The amount of furnace slag

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The fluidity and reactivity of the slag

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The temperature of the steel.

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End point sulfur content is affected by:

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The total sulfur content of the charge

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The lime/silica ratio of the slag

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The amount of fluorspar charged to the furnace

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The amount of manganese in the hot metal.

The end point temperature is controlled by the heat inputs and out put.s •

Heat inputs include:

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Sensible heat of the hot metal

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Uxidation of metalloids

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Combustion of carbon

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Oxidation of iron

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Sensible heats of other charge materials

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Heats of reaction of slag constituents.

Heat outputs include:

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Sensible heat of blown metal

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Sensible heat of slag

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Sensible heat lost to the waste gas

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Heats of decomposition

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Heat losses from the furnace.

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BACKGROUND

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There are many process control strategies available to the

BOF steelmaker. An optimum method for a shop depends on the product mix and the tie-in with the teeming or strand casting operation.

The control schemes can be based on statistical, predictive adaptive control based on static models or highly_ sophisticated control based on continuous or periodic measurement of process variables such as carbon removal rate, temperature, etc. Whatever the control strategy adopted by a ROF 'shop may be, there are a few desirable requirements for good BOF control (1).

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Consistent hot metal quality of accurately known chemistry and weigh t. -

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Scrap of cons Ls t.ent dens_ity and with low harmful res-:Ldual elements such as sulfur, copper and tin.

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Lime, dolomite and other fluxes of consistent chemistry and

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In practice, these requirements are seldom fully met.

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C~ntrol Strategie~

A control strategy may be defined as the means-by which a particular shop or operation chooses to run its furnaces to achieve their aim steel ladle compositions and product quality. A given strategy does have a very strong effect on the number of corrections

whi~h . must be ~~de~fter the. furnace is f~rst t urne d down for

sampling and temperature. These time consuming, productivity destroying corrections may be for phosphorous or sulfur control, to increase or decrease the steel temperature or to decrease the steel carbon. One .cont ro L strategy would be the practice of

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external desulfurization where the blast furnace iron is 4

desulfurized before it gets to the converter, thereby decreasing

the lime load in the furnace and reblows for sulfur. Another

strategy may incorporate rather loose control of furnace and ladle compositions and temperatures with little or no sampling at the furnace. Heat§ of steel may then be applied to Qrders after analysis of the final product. Such practices can produce a very high number of heats ready to tap at first turndown with a rather

indifferent control process.

When comparing process control schemes, the varying definitions used throughout the world is another source of confusion .--. .In some

instances heats which are too hot and are cool~d are not considered

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control problems and a cooled-heat is not a correction. If furnace time is available, the heat may be cooled simply by holding the' steel in the furnace for an extended period. This again may not be classified as a correction •

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The primary differences in control strategy perfornlance reside in the characteristics of ·the decarburization reactions, the compositions of steel which must be made (product mix} and the plant metallurgical requirements and the times required to cool or reb low

a heat for temperature, or to make a correction for a missed phosphorus or sulfur specification.

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Figure 15-1, a typica~ ave rage decarburization efficiency curve during the latter stages of the BOF blow illustrates how the decarbu~~zation curve and the desired end p~int affect the accuracy of a process control scheme. If the desired end point is .30% carbon, an error in the process oxygen calculation of 3.5 cubic

foot per ton of steel will, cause the carbon aim t~_ be mrssed by

.01% if a BOF is employing the l1catch carbon" method of control.

The same oxygen error at .05% carbon will cause a deviation in carbon end point of .001 - .002% carbon. Consequently a BOF

trying to ·ma~~ steel for flat rolled products with a fir~t turndown

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(After Kerns and Stelts) ·

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carbon aim of .05% carbon will have better record of heats ready

to tap at first turndown than a BOF trying to make carbon steels and

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attempting to stop the process at .30% carbon, even though the

process control methods used by both shops have the same accuracy in

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their oxygen calculation.

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Because of the decarburization characteristic curve and as a , carryover of Bessemer and Thomas practice, many steelmaking shops in Europe do not try to make steel by the catch carbpn method.

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These shops blow enough'oxygen so that the steel is essentially

totally decarburized and is high in temperature. The steel can then be quickly cooled in the furnaces and recarburized in the ladle

from .02% to .04% carbon to as high as .60 - .70% carbon, which can give a high pexcentage of heats ready to tap at first turndown with a relatively poor control method. It is impossible to miss an .03% carbon aim by more than .03%. Ii is relatively easy to miss a .60% carbon aim by .20%.

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Shop productivity and apparent process ,control effectiveness can be enhanced appreciably by aiming heats to come in high in temperature-and lower in carbon than the aim, particularly when

making low carbon steels for flat rolled products. It is faster to cool than to reblow a heat and if metallurgical controls are lax, it is very easy to tap a hot heat into the ladle; thereby speeding up the operation and decreasing the number of process corrections. A cold heat cannot be tapped without any process corrections as the results are readily observa~le in the form of large ladle skulls. In addition, if heats are biased to come in low in carbon and·a reblow should be required for temperature, there is often no need to take a second test for carbon, particularly with flat rolled products. If the first_ test was

acceptable with respect to carbon, sulfur and phosphorus a short

_____ . _ .. _ ... reblow._ .. __ will .. .not; have.ichanged --any -of the--components.--.-enoug.h-·-tomake any difference in the steel ladle composition. _.(Of course, if the heats were off specifications with respect to phosphorus or sulfur in the first test, a second test is usually required after correc-

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tive action has been taken to check the effectiveness of the

correction.)

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As an alternate to blowing the heats to a very low carbon level (flat), a BOF shop producing a high percentage of -high and meditm carbon heats may adopt the philosophy of turning the heats down with temperature and carbon above the aims. . Subsequently, a short reblow for carbon with the addition of a coolant generally

brings the heat within the temperature and carbon tapping range.

This is a good practice metallurgically, but the heats requiring a correction for control purposes approach 100%

Numerous metallurgical investigations over the years have pointed out that there is a deterioration in product· quality and cleanliness if steel is recarburized beyond a very limited range,

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or if corrections, either reblows or coolant additions~ are made

to the steel, or if heats are tapped into the ladle and subsequently poured either too hot or foo cold. These investigations have also illustrated that the best product is produced by aiming at first turndown to be at the aim tap temperature and td be at a carbon just low enough so that the aim ladle carbon is reached by

the addition of regular ferromanganese (containing 7% carbon) to reach the steel manganese specification with no addition of other recarb urizers •

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The availability of facilities such as an external desulfurization unit, a vacuum degasser, a ladle stirring device or a spare

BOF vessel can be important ,in determining the control scheme.

With external desulfurization, where the blast furnace iron is desulfurized to a specified low level before it gets to the

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converter, control of sulfur in steel no longer becomes a

critical item.

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With a degasser or ladle stirring device, control of end point temperatures .. in the furnace can be eased to turn down the heats within an expanded temperature range. The temperature can then be adjusted to the teeming specification by coolant additions to the degasser, increas1ng degassing treatment time, or by cooling the heats in the ladle by submerging a cold slab.

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In sumnary, a BOF control scheme may have a high apparent e'ffectiveness as measured by heats ready to tap at first turndown through following a strategy of aiming the heats to finish high in tealperature and low in carbon. ,This is not a practice consistent

with good product quality which requires a process scheme 'designed to finish as near to the ladle carbon aim as is consistent with the ferroal1oyadditions and at a temperature such that no correc-

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D~velopment of P~ocess Control Methods

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Converter control methods did not start with the BOF, early

installations followed practices which had been developed for use in Thomas and Bessemer converters. In turn, bottom blown converter practice was largely an art with varying degrees of effectiveness; the temperature of the process was estimated by eye or with the aid

of optical pyrometers. The end point of the blow (and carbon content) was estimated by observing the flame at the converter mouth, the color and intensity being an indication of 'the course

of the decarburization reaction. As the decarburization efficiency dropped near the end of the blow the flame intensity also dropped as less oxygen was used to form carbon monoxide and carbon dioxide and more was used to produce iron oxide. By judging flame intensity a Bess.emer or Thomas blower could halt the process when

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his desired end point was reached. This end point was generally at a very low bath carbon content.

Spectroscopes had been us ed to observe the Bessemer flame for control purposes.in England as early as the 1860's. In England and the Uni ted States, ae Lenf.um photocells were used to measure the

light intensity of the Bessemer flame and to control heats during the 1940's. G. Naeser and K. Krachter (2) reported. on infrared measurements from Thomas converter .flames. This work gave curves that

enabled the refining processes to be followed, but the temperature

was still an unknown and caused. fluctuations in flame intensity. Later, workers inv.estigated converter flames using different regions

of the spectrum and a technology was available for transferral to

the BOF. ._r

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Early North ~erican and European BOF installations followed Thomas and Bessemer practices as a control means. However, as the BOF process spread in North America, and as more and more steels

which were formerly made in the Open Hearth were made in the BOF, a need developed for better temperature control and, eventually, for better carbon control than was possible using visual observations and estimates. It was possible to sample the Open Hearth and determine composition and tempera·ture and, therefore, steel-·

'making practices had developed based on knowing the composition and on catch carbon techniques. There was some incentive to apply this to the BOF. In Europe a large proportion of-tne-steel product was

made in Thomas converters, the steel was blown to a very low carbon . level and recarburized in the ladle and i]litial1y there was not the incentive to develop predictive control methods and a catch carbon practice.

Also, when t~e BOF was used in Europe in conjunction with ThoDlasiro.n (1.6- 2 •... 0% phosphorua), a.two-slag.p,rocess was

required to produce low phosphorus residual steel. The converter was stopped in the range O~75 - 1.00% carbon, a composition check was made, the bath temperature measured and the in'itial high phosphorus slag was removed. At this time a second batch of slagmaking materials was added, the blow resumed, and any corrections for temperature made •. Good temperature control could be assured

because of the short period of this second blow.

Process control methods for the BOF were stimulated by the simultaneous development of other technologies throughout the 1950's and 60's. With the rise of the computer, first analog and then digital, it became possible~Lomake many complex calculations

before the' blow started. Improvements in weighing systems and load

•

ce Ll, technologies made it possible to accurately weigh all input

materials. Direct reading spark emission spectrographs had simplified and speeded chemf.ca L analyses of steel. Since one was now able to analyze and weigh furnace inputs and outputs and since a process model could be used with a computer to calculate a mass

977

BOF S.teei.mating

and thermal charge balance, the assumption was made that now one should be able to control the process reliably.

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It -was recognized (3) that the relative proportions of hot metal and scrap were a function of hot metal silicon and hot metal temperature and charge makeup was adjusted in response to changes in iron compositions and temperature .

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In 1958, W.O~ Philbrook (4) presented a paper demonstrating that the BOF steelmaking process could be approximated by calculations based only on mass balanc~s and thermochemistry. Shortly thereafter, a thermochemical-process model which was used in an operating BOF was described by W.J. Slatosky (5) of the Jones and Laughlin Steel Corporation. The first version of the static thermochemical model was solved witlf a special slide rule. This

was quickly followed by a special purpose analog computer and later by a digital computer. Meanwhile, other companies in Europe and Japan were building static models for process control •

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As inadeq~acies in the basic predictive static model appeared, adaptive statistical versions were developed. Some examples were descr-Ibed by Katsura et al (6) and Nakata et al (7). These model~ were outgrowths of the operator practice where a man might decrease the amount of coolant, blow more oxygen, and/or increase the amount of- hot metal if he found that heats were turning down consistently low in temperature. The models were adaptive in

that they used the results of the last heat or last few heats to

_ make changes - in the upcoming heat charge based on changes in charge--·

material weights and analyses, and changes in blowing and converter conditions. The control equation coefficients were modified from heat to heat and were developed by linear regression analyses and other statistical methods.

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A logical outgrowth of purely predictive m~dels was off-gas

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analysis, an a~tempt to continuously measure the quantity of carbon

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being removed during the oxygen blow and, by integration, to de-

cermdne the residual bath carbon.

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The IRSID (8) organization was the first to attempt this method of control. However, small errors in analysis, gas volumes and carbon input· values, when integrated over the entire oxygen blow, yielded large errors in the_end point prediction. The next approach, again originating at the Jones and Laughlin Steel Corpo'rar fon , was extremely ambitious and sophisticated. It is pos-. sible to develop the course_o~_the decarburization reaction with time from the gas analysis curves during the oxygen blow. The curve may be expressed as either the amount of carbon removed per unit time if the lance oxygen.input rate is constant or preferably as the mass of carbon removed per unit of lance oxyg~~ injected, an efficiency term. Figure 15-2 shows a typical decarburization efficiency curve plotted against bath carbon for a single heat.

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Ff.g', 15-2: Typical Decarburization Rate Curve from Waste Gas Analysis (After Kerns and Stelts)

At the start of the blow'-carbon removal efficiency iso-low as

lance oxygen is being 'used to remove metalloids. After about one-third of the blow, the carbon removal reaches a maximum efficiency and then starts to decrease. This latter part of the curve can be appro~ated by an exponential decay function. After a preliminary examination showed that the decay function was not similar for all heats, Jones and Laughlin-embarked (9,10) on a dynamic control system development wherein the basic assumptions were that the exponential decay function for a given heat could be calculated

- - whi-le -- the--heat .. ~was --- in'- progressend ,tha-t, -af-terthis - - funct-ion was

established, it could be used to determine the instantaneous bath carbo~ and the. oxygen required to get from the bath carbon to the

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aim carbon, The bath temperature was determined independently during

the latter part of the blow by dropping an expendable weighted thermocouple into the furnace. An estimate was made of the final

bath temperature based on the thermocouple reading and the amount of oxygen whic~ remained to be blown •

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There were alternate versions of this scheme developed by other companies. Some used a single averagedecarburization curve for

all heats, some used oxygen in the waste gas or waste gas temperature (third order effects) as an alternative to gas analysis, which measures a second order effect (carbon leaving the furnace as carbon monoxide or dioxide) and seeks to relate this wi~h bath carbon •

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A third type of approach, implemented during the late 1,960' s and early 70's, was to supplement a basic charge model with some

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kind of in-furnace measurement, either of carbon or of temperature • This information could then be used to make any corrections required to meet the aims while the heat was still in progress.

Investigators of VOEST (10) were one of several groups who spent considerable effort in an attempt to develop a continuous reading thermocouple which could be inserted through a vessel shell and

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lining. After encountering problems of thermocouple sensitivity and

life, VOEST abandoned the approach and developed a continuous read-

··ing thermocouple sheathed in a cermet which could be lowered with a lance into the furnace bath, lasted through several heats and could be replaced on a periodic' basis. Fradeneck (11) received'a patent in 1967 for a secondary lance for automatically inserting expendable thermocouples or samples into a steel bath in an upright BOF. This equipment was utilized by Kern and Stelts (12) in their development of a process control method 'and sensors for in-furnace detenmination of carbon and temperature. The process consisted of stopping the oxygen blow for a short period of time after about ninety percent

of the oxygen calculated to reach the end point had been blown, obtaining a temperature and carbon from the upright furnace utilizing a device combining a standard thermocouple for bath temperature measurement and a thermocouple situated in a sampling cavity

to obtain a carbon detet:mination by the liquidus arrest method. Corrections could then~Wamade during the last ten p~~cent of the oxygen blow to meet the first turndown carbon and temperature ajms. The sensor lance approach has also been under extensive development in Japan (13, 14, 15) where the concept has spread rapidly with

great success in decreasing tap· to tap times. "-.

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A,ims" <?f Blowing C9ntrol

.. _ . ......__. ... . __ ._~. __ ~ . __ The ~rim~!:y __ 9bj_.ective __ _9_f __ ~ef!ning .. _~r _J)~o~ing_~C;;.Qntr_C?l. is. t.o ..

oxidize the metalloid jmpurities in the charge and to form a basic

slag as rapidly as possible in order to protect the lining and to permit adequate sulfur and phosphorus removal. The control of the refining cycle can be attained by a proper combination of lance practice, flux practice and oxygen flow rate. It is essential to develop a refining strategy which forms an early basic slag and

.maximizes carbon'removal rates without adversely affecting the lime solution and sulfur and phosphorus removal, and which minimizes slopping and ejections from the vessel during the blow.

Development of Blo~.ing Control ME7,~h.ods

Concurrent with the developments in end point control, blowing control was under development in Europe and elsewhere. The

European incentive for blowing control of the BOF was 'similar to that for Thomas practice and evolved from the need to keep the' large quantities of foaming slag developed in the blowing of high

980

oil

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phosphorus Thomas iron in the furnace. Further practices in Europe and the United States were developed as the desulfurization required of the converter processes increased because of both the use of higher sulfur hot metal caused by coking coal shortages and the subsequent use of high sulfur coke and a demand for lower sulfur steel product. Also, as BOF_heat sizes were increased, vessel volume per ton of steel decreased and there was a need to minimize slopping.

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Parsons and Shewring (16) have reported on the use of an audio-

meter to monitor slag foaming and to 'act as a guide for oxygen

lance control in an LD-AC operation. In an alternate approach an

......

insulated probe was developed (17) to extend beyond the oxygen lance

and to measure the slag conductivity which was a function of amount of foaming and the slag composition. The lance position and"oxygen volume were changed to control the process. This was claimed to

get around the problems of. random plant noise and interference from

.... ... ¥£222 .. "I' .I

other converters associated with acoustic met.hods , Vertical. vfb ra-

tion (18) measurements have been used experimentally to determine the extent of foaming. This method has not been developed commercially. The Centre Recherches Metal1urgiqu~ (CRM) acoustic and fume temperature (19) sensors for. controlling slag foaming now

..... ....._..... ..

predominate. In the latter approach, the fume temperature is

empirically correlated with the decarburization reaction in the , furnace. The fume t.empe ratnrre thermocouple has good stability and overcomes theproblenls of time lag prevalent when using infrared analyzers for obtaining the decarburization rates. Gas analysis using infrared analyzers has been proposed (20) as a means of blow- · ing control. This syst~n proved unworkable because of the time lag

of the ·instrum~ntation and because it was impossible to separate a

decarburization perturbation due to incipient slopping from the

normal noise· in the decarburization systems (see Figure 15-2). In Germany (21) an extensive experiment has been made utilizing a mas-g-'--'siJe-c f-i-ome-f-er ' to- ~aiialy ze ---the- 0 f f'" g'as-~"-----Tne--'- 'tlme~-6 f ., -r-lfght

spectrometer overcomes the time lag problem of the infrared gas analyzers. Waste gas flow was measured and the amount of lance oxygen used to decarburize the bath was calculated as a function of oxygen flow rate. In the experimental installation, the information

was collected on a digital computer and used to calculate the total heat flow rate. in the off gases (a function of the sensible-heat in the gases leaving the furnace plus the chemical heat of the carbon

-monoxide-carbon dioxide reaction in the hood). The actual heat flow QA was compared to a theoretical heat flow QW' based on a

desired heat generation curve, and corrections were made to the

~

oxygen flow rate and lance height to maintain the proper heat flux

in the boiler hood. The current system status is not known.

...

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981

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END POINT CONTROL METHODS

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Flame Characteristic Control

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As mentioned earlier, -visual observation of the flame at the BOF converter mouth was and is one of the conIDlon methods of determjning the end point carbon for low carbon heats. "

-- ', .. j

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In Bessemer and Thomas pract~ce there was also much use of spectroscopes, selenit1~, pho~ocells; and infrared 'cells to monitor the flame and estjmate end points. Because of the similarities

between the decarburization stage of the bottom blown process and the latter stages of the top blown oxygen process~s, similar techniques of measuring the radiant energy of the flame were used fo~ end point control in the BOF. Parsons and Shewring (16) have

reported on tests using a~ phe£emetric apparatus where four regions of the spectrum were analyzed:

o

•

-

A narrow band in the visible violet at 4300 A

. --------

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A diel·ectric filtered in the ·visible red a~ -6300 A

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A broad band in the near infrared extending from 0.4 ~m to 3.5 ~m

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A broad band extending from the visible region to 8 um in the

infrared

•

The flame radiations show characteristic variations in emitted intensity. The radiated energy reaches a maximum and then drops rapidly near the end of the blow depending on the type of radia-' tion. Af.ter a comparative study was made, an examination of the

" u, -'-"control" possib-±li.ties-was -made-- -using-~the- 'infrared-p-orti'on--of-the " ,

spectrum. The degree of carbon end point control exhibited in the

•

control tests was quite modest. ·

In the United States Ray-O-Tubes have been used to measure

flame intensity. The results have not been pUblished in any detail.

An experimental survey perfoImed by the Bethlehem Steel Corporation with two-color pyrometers and spectrophotometers operating in the near ultraviolet and in the near infrared was unable to find any

correlation between bath carbon and measure~ intensity at steel

bath carbons over 0.10% and only a very poor correlation, unsuitable for close control purposes, at carbon contents lower than 0.10%.

Limitations ~f Fl~er D~op Measure~e~~~

The basic assumption of any flame drop control method is that the radiation intensity is a function of the decarburization rate,

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and in turn, this is a function of the carbon in the bath. Flame

- ~

intensity measurements are two steps removed from the variable

which is to be measured and are related by approxjmate functions. The possibility of using such instrumentation is restricted to making very low carbon heats. and the end point c9ntrol attained is not satisfactory for the more stringent present-day needs •

..

STATIC MODELS

..

-- --

Predictive Models

... _PSI ... ...

• ..... - I'_"

The thermochemical and mass balance relations which can be

used to establish a static model calculation have long been available (4). Healy and McBride (22) have discussed the basic system of eqnations in this monograph. With only minor variati-ons, equations of this type have been rewritten as control equations and static models have been established using printed .tables, graphs, -special. _

s11de rules, analog computers, digital computers, and combinations of digital computers and sensing instruments as technology progressed. In this section tlie progression of these models and the changes in the basic process assumptions are discussed.

Slat~sk~ Model - As mentioned above Slatosky (5,23,24) published the first work on BOF furnace control. The original aim of_ the

control scheme was to control only temperature. At this plant all

heats were charged based on operator judgment to a constant weight of hot metal and scrap plus varying amounts of lime and blown to the same low carbon aim. If there were changes in input materials, or if the p revd.ous heat was outside the desired tapping temperature range, empirical estimates of the' necessary changes were made by the operator. In an effort to devise an improved method for

·_··tempe rature=eon t ro 1 ,m_·an-·-ana1ys is . of-·---thew-- p roces·s- - -t hermochend.stry was completed and mathematical equations were developed which eventually enabled calculation of the quantities of scrap, lime, and hot

..

metal~needed to reach a given temperature range. The first equa-

tion developed from the heat balance analysis yielded the pr-edicted temperature as a complex function of the main input variables; hot metal weight, temperature, silicon content, manganese content,

~

. scrap, lime, mill scale and iron ore pellet weights and lance

height. After determining that the equation could estimate tapping temperature ranges, a set of control equations was developed to

y~eld the zequf.red amount of scrap necessary to meet the charge conditions of hot metal weight and composition, tapping temperature,

lime silica ratio., and lime weight. These equations were used in

control tests utilizing a complex s Lfde+ruke to establish the charge for the furnace and-the method was found to give a level of temperature control. Since operation of the slide rule was subject

to error, an analog computer equipped with a printer was designed and built to solve the simultaneous equations of the charge model.

983

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~, BOF Steeimdh.ing

~

, · I

In this computer, potentiometers were set for desired charge weight and tap temperature, basicity ratio, lance height, scale and ore additions, and iron ore silicon,-manganese, and temperature. After these inputs were read into the computer the charge quantities of scrap, hot metal and Ijme were printed. An evaluation of this model showed an increase in control over operator control but there

· was still considerable room for improvement. It was believed that the road to better perforDlance led through model refinements, improved chemical analysis, and more reliable sampling methods.

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Boltz Model - The model described by Boltz (26) was developed for use with a digital computer. Following the assumtions of earlier authors such as Slatosky (23) an extensive effort was made. to

furnish reliable inputs and complete chemical analyses and weights. The system was designed to control carbon, temperature, sulfur, phosphorus, total oxygen blown, and tapping weight. Inputs were read into the computer automatically so that the operator had only a minimum nl~ber of operations to perform. The solution of the simultaneous equations was iterative and the calculated charge was

printed on a teletype. Recognizing that there might be long or

•

short term. swings in furnace t.urndowas, the program model had bias

switches so that the charge model could independently incorporate .. biased amounts of either oxygen or temperature into the calculation. Figure 15-3 illustrates the charge model flow sheet.

Section A contains all computations which occur_ only once pet charge . calculation and include the average scrap analysis, oxygen required for decarburization and heat terms associated with unit weights of iron ore, scrap, slag, fume, and lance oxygen. Section B contains computations which may be performed several times depend-

ing on the problem. These. include weighted average hot metal analysis, heat terms from the iron and steel., estimated heat losses, an-estimate of refractory loss from the lin.:ln_g t~ __ ,_th~_. __ sl~g, __ t~~ .. _ ._ .

... .. --_ _ .. _--- ._- ----_._----- -~- . - ----- ------- --------_ .. _-------- -- .

amo~t of iron lost as fume and empirical relationships establish-

ed from shop operating data which are used for sulfur and phosphorus control. Section C illustrates the possible cdmbinations of known and unknown factors which may be used in the simulatenous solution of the heat and iron balances. Usually the first iteration is based on- a known steel product weight desired and a known weight of scrap available in the scrap box. Final computations in this section are calculations of the lance oxygen, burnt Ijme, slag FeO and slag weight. Section D contains checks on whether the .. metallic charge and slag weights for the iteration are within the preset tolerance- from the previous iteration. ·

If they are not, another iteration is initiated. If the weights are outside the tolerances, the program then checks the preset

...

tolerances for the ore weight. If the ore weight is outside the

ljmits, another iteration must be started. If the ore is correct, the program continues and checks if the hot metal weight poured is greater than the calculated hot metal. If it is, another iteration

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is started. If the weight is less than calculated the charge quantities are printed for the operator. Although the model was developed from a theoretical thermochemical basis it has many empirical relationships describing slag formation, FeO generation, phosphorus and sulfur removal, decarburization efficiency, etc.,

which can be adjusted periodically if a data review indicates that changes are necessary because of long term changes in operating techniques or charge materials. The basic mode~ is used in four BOF.shops and .is adjusted to suit the operating conditions of each.

BOF ste..e1.ma.lU.ng

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~~ ~~~_e_l - Figure 15-4· illustrates the flow chart for the CRM Model of the BOF process taken from th-e paper by Dauby et a1 (27).

The flow sheet is similar in some respects to the Boltz model

'discussed above, but it has two ad·ditional important features of interest-~ First, after the completion of the· blow, analyses of steel, slag, and actual quantities charged, are used in an afterthe-fact calculation to deternline oxygen effi-ciency and _d_!~ferences between calculated and actual slag and temperatur~ conditions.

The corrected factors are then used in the next heat calculation. In practice (28) the changes recotDiliended by the calculation on the previous heat are subject to a damping function so that the changes of several suc-cessive heats. are used for correction. If the data are suspect because of some operating anomaly the data and suggested corrections are rejected.

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The second and more jmportant area where the CRM calculation differs appreciably from those discussed earlier is in the.calculation of the slag vol1me and composition using physico-chenical principles. From the phase diagrams of the slag system, correlations have been established between steel sulfur, sulfur partition ratio, and slag weight. Additionally, the lime saturation boundary in the pseudo-ternary has been defined in terms of the slag iron

·---(for---a--nOF -- p-ract-ice), and - -a-system---of----S1X-- equati-orHf wi-fll six-un';'

knowns established for the slag describing the interrelationships between the principal slagmaking components Cao, MgO, MnO; Si02, FetO and P20S. _For each slag iron content the amounts of the other five slag components can be computed from the s~ultaneous equations. For each slag composition there are definite P,- 0, C and

.................

Mn contents and an (8)/ S ratio established.

~

-

- _____

---

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In order to meet the several simultaneous requireuents such

as maxiwnn phosphorus, maximum sulfur, and carbon, the slag iron contents necessary to meet the most stringent requirements are found by iterative calculations, varying slag iron along the lime saturation line until a slag composition is found consistent with

the chemd.ca L requireolents of the steel. -.

..

This static model has been used with charge tables and with digital and analog computers in many European steel plants· with

986

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BO F Stee1ma.lUng

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(After Dauby et. a1. 27) .

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good results. An Lnsca.l Ia t Lon of interest is that at the Cockerill. plant in Belgium (19) where the static model calculation is by digital computer. Additionally, an analog computer was ... used in conjunction with ftme temperature and acoustic noise measurements to control slag~formation kinetics by altering the lance height and oxygen rate. The results indicated some improvement over the static model alone. The predictive static model and the blowing control

..

loops were to be converted to an all-digital computer system (19).

-

Statistica'l Models

- r

The derivation of statistical models follows directly from the earliest operator controlled practice. If a heat turned down low in temperature, the operator woul.d tend to blow more oxygen or add more hot metal for the next heat. As more input data became available with time, operator corrections would be made for changes in hot metal silicon, etc. However, as the technology advanced,

". the number of inputs increased greatly and their interrelationships are so complex that an operator could not make an empirical correction with certainty without aids such as special slide rule, or eventually, a computer.

Unlike a predictive model, statistical model development has

been such that the·structure of the model has not developed with time as the understanding of the process progt'e·ssed. The models are based on the change in input variables for the same limited nlmber of recent heats and the changes in the equation coefficients are established from least squares multiple regression techniques.

•

Kat!>.~ra,z Isobe, Itaok~ _~o_del - The model described by Katsura et

p

c.l.~l . ( ~) is ~.yp ~£.,~~.9 ~th.~ ... s r. eps und e 1;'.t~~~I!~11 ~.~.~.~.:j_~. ~i~~J .. JIlQde 1 deve -

lopment. After an initial predictive model y~elded large deyiations

between predicted and actual results, effort was expended on improv-

ing the assumptions of the model. After little progress, an attempt was made to correlate end point temperature with input variables using mUltiple regression. analysis and plant experiments. Some

small improvement in end point temperature prediction was obtained • I t was next assumed that rela tively .Long term changes in the .

process were affecting the sensitivity of the regression technique and therefore a control equation utilizing the data of only the

last previous heat was developed. Utilizing this data, the estimat.ed end point of the upcoming heat could be expressed as:

T = T +[f(X1)

u p u

+

f(X2p)] + ..... (15-1)

..

where Tu is the estimated turndown temperature of the upcoming heat. Tp is the measured turndown temperature of the las~heat. Xl,

X2 ••••••• are input weights, analyses, and end point conditions and £(X1) is some function of the refining variables, for instance an

989

, . .

..

......

"" ·1

""r#- " r

.

~

1

. . ~ :..~ _ i

-, ,

- 1 _I

- . I

I

\ -

J

-. 1

.

Charge models were and are established on the basis that if

inputs could be measured accurately, and if the process could be described accurately, the end points could be predi~ted accurately. A secondary assumption was .that, if the above initial assumptions were correct, any other process changes would occur slowly and in a regular, predictable, manner if a11.oxygen lance variables

were held constant. Therefore, it was assumed that if the heat did not turn down at aim, it was because all the inputs were not measured or weighed accurately, the thermochemistry was wrong, or

operator adjustments were made-which changed the predicted charge • Extensive effort went into designing systems with better input

•

analyses, weights, and instrumentation. These systems showed some

slight improvement in end point control over earlier models, but the improvement was marginal. Papers (29,30,31) calculating the

amount of deviation in turndown temperature which could be expected based on variations in input variables were published.

BO F Ste.eimalU..ng

exponential to describe the removal of carbon by oxygen at low

•

carbon concentrations or a straight line function to describe a

difference in manganese concentration from heat to heat ,

This temperature version of the equation was converted to control equations. In this case iron ore weight was used to control turndown temperature and the iron ore for the upcoming

heat was expressed as a function of ore from the previous heat, change in temperature desired, changes in input weights, analyses,

.11 ~_ ...

and temperature and functionS relating to the turndown carbon aim

and blowing practice. .A_con~rol equation for total oxygen was developed in the same manner to control the carbon content.

The calculation procedure was:

•

Hot metal and scrap were weighed

•

Hot metal temperatures and analyses were obtained

. The burnt lime requirements were calculated based on the steel phosphorus aim

•

The amount of ore required for t he rma L balance was calculated

•

The amount of oxygen (lance plus iron ore) was calculated

._- --- ~.

-

• The total steel to be produced during that heat was calculated

based on the weigh t of charge ._ . __

Operating data.were collected, analyzed off-line and used to modify the control equations.

Limitations or Predictive and Statistical Models-

..

990

.....--

15-BOF Con:tJwi

+

· .-" "' ...

- ~ ~. .f..

... . ~ . ..:..

"':yr~ <:

.......... iii- I

- .•• ..A"j

........ ~ P'

... _,

.ot.¢ ..... ~- 1

l: .... ~ ":'.l !i',\. .. " · ..r~...;, ... ,

~;;1

... ~. ~ :'" i

_,.._~ t

. \~ ;

t: , ..

• - I' .. - ...

- .

One very important point made by Meyer, et· a1 (31) which has been often overlooked When workers are trying to establish a theoretical heat balance, is that the difference between the calculated slag iron oxide and that actually achieved can contribute in theory more

variance to the turndown cemperarure than is realized in practice. For instance, it is conmlon in United States BOF practice for low carbon steel to have a calculated aim FeO in the order of 22-25%

---

(total slag iron as FeO). However, the standard error in turndown

results (FeOActual - FeOCalculated) is not uncommonly +6%~ a

relative standard error of +25%. If a 1% relative error in the slag FeD is estimated to cause a 2°F change in the t.urndown temperature, a 25% relative-er~6r should yield a standard error in temperature at turndown of the order of 50oF, exclusive of all other input or model errors. In actual practice, the standard error in turndown temperature in United States BOF practice is usually of the order of 30-4So~.

! • ,._ I :...f ...... .....,.. . j •• ~~ .....

- 't.. ..... ,. :

. L" ... •

1 """I! .: r;t".~ . .,

.. . III _

• 1IIIIIri.. p ~

........... , ~ .- .

- ..

- . ~

- .

Meyer, et al (31) postulated a self-regulating mechanism in which oxygen for slag FeO formation and oxygen for burning carbon monoxide to carbon dioxide inside the furnace vary inversely with each other. The heat of iron oxidation and the heat produced by oxidation pf carbon monoxide to carbon dioxid~ are not greatly different at 2900 F (-56.9 kcal/g.m. and -66.6 kcal/g.m., respectively). This mechand.sm, .. has never been proved, but it. is a reasonable explanation to account for the fact that the temperature error calculated from the error in slag FeO is often greater than the actual error in the temperature of the converter heat •

•

11ethods of end·· point control using gas analysis are discussed

in the next section but the results of-extensive gas analysis and dynamic control expe rdment;s can throw some light on the l~mitat-ions -of pure static model systems. Gas analysis techniques allow one to

···ca:l-ctilaee··-··-tlie·-··aecarouriza-tiotf-'·efficienci-es ···wl:to·--resrpeH:t--t-o ···either

mass of carbon removed per mass of lance oxygen injected or the

mass qj carbon.per unit time. The decarburization efficiency per unit. of lance oxygen is the more universal as it can compensate for changes in lance o~gen rate. For display purpose, the decarburizatian efficiency may be plotted against time or carbon throughout

the oxygen blow.

One of the basic premises of ~redictive and statistical models is that if the heat is blown at the same lance height and oxygen rate the decarburization efficiency and thus the heat generated

will be the same as that of the preceding heat. All the evidence

from gas analysis indicates that this assumption is incorrect.

The decarburization efficiency may not remain the same for heats charged with similar materials and blown in the-same manner. This change in decarburization efficiencies, which also affects turndown control, is not predictable from heat to heat, and there are no' observable trends.

- "I' - • ... ..... _ ...

991

. _. I

-_._........._....

-_.

BOf S.teei.ma.king

,

The variations in static model performance and decarburization efficiencies and kinetics have been ascribed to changes in the hot metal or scrap makeup or to changes in analyses. It has been hypothesized that if the hot metal and scrap compositions were constant, or only changing slowly, and if only one grade of steel

were made, it would be possible to control heats and turndown aims to a very high degree. Work done by Bethlehem Steel (32} would indicate that this may not be true. Although ·no -mdxe'r was available for these experiments, all submarines were sampled for hot

metal analysis and a weighted average composition was-obtained for all heats and used in a rigorously followed static model. The plant makes essentially one prod1:lct and essentially one aim grade. , All

scrap was home scrap and was consistent in size, quality, and composition. Blowing conditions were kept constant ,and the results were:

, • - + •

.... r ~_"~: • -.:. ( r·

, ~ '1

.-, + ~ 1

.. t_ r _ II' ..

................ .

,~ .. : .. ;...,:_

-,' .;. ~ ...... • ,rof_" •

.; ~ . .t ~_.-

- ......

....

- l

. I

.. J . . 1

• Decarburization efficiencies as measured by gas analysis were not noticeably more reproducible or predictable than those obtained from a sister plant utilizing many different types of scrap and making many different carbon grades.

.. ...,

~ - . 1 - . 'I

. . , , .

•

Static model end point carbon results were no better than for

. .

the sister plant •

. ,

•

. .

. --

• Temperature control was slightly-better than that obtained at

the sister plant.

-~ ...

4 J

• t

t

I

These results indicate that the mechanism for obtaining

-

reproducibility in static model operation may lie in other unde-

fined areas besides "those of constancy of inputs and outputs.

•

It would seen that the best promise of end po Irrt . static model

_. ... .. __ , --con~rol may be achieved by the techniques described for the eRM

(27, 28) model.----- This involves the useOf- a welf--ihought o-ui:-

physical model, aided by good inputs and supplemented with instrumentation to force the blowing characteristics in desired directions. However, significant improvement in turndown control has not been achieved when using static models alone.

GAS ANALYSIS AND DYNAMIC CONTROL

l~teg;!1ted:_Ca_:t:.bon lI~on!:..rol

'p- _.~

The IRSID organization reported (8, 33) early r~sults based on analysis of the offgas from a converter for control of carbon.

The system was based on the principle that if one knew the inputs, particularly the total amount of carbon char geds- -one had only to analyze the percent carbon in the waste gas (present as carbon dioxide in a complete combustion wa~te' gas system), measure the

volume of waste gas, de t e rmf.ne the pounds of carbon leaving the

..

992

...

.. • .• + ..•

. '.

, .

hrrors are introduced-into the system through small errors in the waste gas volume, instrumentation, and uncertainties of charge carbon brought about by errors in hot metal analysis, variable amounts of kish on the transfer ladle, variable amounts of carbon

burnoff during the hot metal charging sequence and varying

•

quantities of calcitm carbonate present in the lime charge.

. - ....

15-BOF Contlw!

..

. ,

":,;. "_ .. ~. r

1M - ...

... .-. _. .

..... ~~. -: ~.

-~ .

...... ...

~ ~ '" .

z::: ~ , ............ ~.

· rrI'-''';~.-t -l .. jlr .: _.~ •

. ,...,,~ ..

· . - .... -.

-"', .. ,- -_

.. . ....

1'.. . ·"\.i

- ... I

.... ,. ...

'I - _ ._. ••

I _ ~ ..

11..... ..

. .. .;.. - -

... .

.... ~._ r •••

~ .

..... _ rb· ~

............. T~ I.:

• • T

• • • 'I

, .

furnace per unit time and by integration, determine the carbon in the

-

bath at any time.

.t

C t

c -

•

1

o

d_Cdt dt

(15-2)

In equation 15-2, Ci and Ct are initial carbon and carbon at time t. Dukelow, et al (34) have described an early experjmental installation which utilized a carbon integration technique.

~

- ......

...... .. • '*" •• .,

..

In view of these large potential errors, when the large amount -of carbon in the decarburization sequence was subtracted from the large am~~t of carbon in the charge in an attempt to predict the small amount of carbon present in a typical steel, it is not

.

surprising that the technique rapidly passedrrom the scene.

T .' -

..

. . ~

_.. .

~ .

t' .

-

•

. ' .

I?e~arburizatJ:o.~ Mo_d_~~ .. (Dy_nal1!~~ ,<;; .. ontro_l.)

.

" ~

The next attempt at BOF control, an outgrowth of the integrated carbon experiment described by Dukelow et al (34), was the most sophisticated approach to direct BOF computer process control ever undertaken. It recognized many of the problems due to the variability of the process, even the in-furnace variability, and attempted to solve them. Reviews of the published literature show many

"lafer"-'sim:flar--'iittemp E's- -" at"" - d:ynam1c control -o\it.-none--"--or"" -the "Lacer

systems attempted to deal with the in-furnace variability to the extent that the Jones and Laughlin dynamic control scheme did ...

The system has been described in a series of publications

(9, 20, 35) and is based on the exponential decay characteristic exhibited by the decarburization efficiency curve (Figure 15-2) in the latter stage of the blow. Earlier work (16), such as flame drop

methods, had assumed that the decarburization efficiency was directly related to bath carbon and that, if blowing condi-

tions were maintained constant a given value of decarburiza-

tion efficiency or flame radiation indicated the same bath . carbon for all heats. Experimental work based on this premise quickly showed that even if charge and blowing conditions were maintained constant, decarburization efficiency was only a rough

indication of carbon content and was not suitable for end point control. Later 'Work, disc.ussed by Shimata, et al. (36) clearly illustrates the rough correlation between bath carbon and

- - . . .... -.-...._.._ .

993

'1"'11 .. --

.. ..

BO F S.te.ehnafUng

~dc/dt (ko/mi

•

•

400

/ .",-

;' fill"

./ .,;-

0.. .. ;'" 0

... . .""

o 0 0""'- o,_.

.tJ' ._./ .0 e...,f'o

~ --V.". _"

. .. Or· ,./

~ / .

• 0. -/.. ." G •

• • .04" ~tr. . '0

• • •••• oY .. • ;'. •

.. . "'" ... " .

• 00• • _J •••

. ...." ~

.. ~ .. ' ". . .

... o. t?' • :'_'/ • ..: •

til. < • .."

....,. ~

• _: /0. _//.

• 0. ( •• 0 •. 0-

G.. / .

..-. ••• • 0 .• 0." . •

~~.~ •• _. ~,J • ••

.- T -~ ...I.. 00 0 0 ......, : • .J.: .... •

,... ... . ~ ......

~ •• ··0 .~~. • •

, ... •• °e ---.. •• •

t' ,.:-.~.........

.... ...- ... ~... -

. ,._.,.

. .. ~ ..

. ",... .

. ,

•

600

•

o

J t

:! 500

I)

...

•

•

c
0
. -
...
G
..
--
....
~
.a
..
1 a
. - U
at
"0 300

•

•

•

•••

..
. - c 200
~ ._
0
A.
13
c: SOO
I.&l
. •

OJO 6~' O~20

End poin' carbon content (%) (After Shimato et au

--

Fig. 15-5:

Computer Control of Oxygen Converters

, ..

. _ __._..

decarburization efficiency (Figure 15-5) •

..

. I

,

The assumption behind BOF dynamic control was that, although

the decarburization efficiency was not directly related to bath

carbon for all heats, "i,t J!~~ I fAO~ the h~8:.~", in Er~gx:~~,~. From this aasumpt.Lon , and from the decarburization efficiencies calculated

from the gas analysis and"mass flow equipment, it was possible to calculate the coefficients of the exponential decay equation as the heat was in progress and then from this equation solve for in-

stantaneous bath carbon and .the amount of oxygen required to reach the aim bath carbon. The raw data were collected and smoothed by an on-line digital computer. The computer could update the calcu-

" " - -" -"l-a fion"n_" every-""" f i ve:--sec"onds "; --ag""-il "riew""" s e tOo f--ins" fan tati"eous----3ci tawcis

received from the analyzers and mass flow equipment. This exponential equation describing the latter part of the decarburization process may be written as:

1

R = R (1 - exp [-K (C-Co)] p

(15-3)

where:

R is the instantaneous decarburization efficier.cy expressed as pounds of carbon removed per thousand cubic feet of lance oxygen blown.

Rp is the maximum decarburization efficiency encountered during the course of the heat.

K is a constant for the heat in progress.

- .. -,;J-A..~

994

..

..

15-BOF Contltol

.

.. .... .... ... ..;..-

C is the % carbon in the bath corresponding to the decarburization efficiency R.

-

C is the extrapolated bath carbon content when R equals zero o

The equation may be rearranged to:

- .

- or ~

'I·

(15-4)

.. 'I" I ..._.

.. I

There are mathematical methods for solving the coefficients of the exponential equation and then determining bath carbon. One can use nonlinear least squares solutions or differential

techniques. I

+

, . .

One of the simplest methods is to:

..

..

.

(1) Determine ~ either as an average of R values measured

over the middle part of the blow or to determine ~ after the decarburization efficiency has started- to decrease in the latter part of the heat using inspection and comparison techniques in the computer program •

.

... -

~ . .

-

(2) After R starts to decrease from the maximum R , it is

possible to calculate the curvature coefficient K by dif¥erentiating equation (3) with respect to carbon.

-

,

-_

•

dR

de = K

(R - R) p

(15-5)

and

r'

.....

.

- . ., ~

K = dR / de

(15-0)

(R - R) p

.. .

L. •

or

K = (AR/~C) / (R - R) p

(15-7)

+

Rand C are obtained over a suitably short elapsed time, depending on furnace characteristics

--- .d i ....

or

~, ...
R2 - R~~ Rl + R2
1
Rp ......
K ... 1.l1li
-
- (15-8)
C2 - C1 2 995

..

.. - .........

............... '.~

.. rJ" ~ ..

'" "".

.. . .

j t

..

j

,

.

I

I

1

-

•

BOF stee1malU..ng

, ~

(3) The value C is small, usual1v of the order of .015-.020%

and may be obtained fr8m historical data~ or treated as a constant.

(4) Having obtained Rp and K, equation (15-4) may be solved for bath carbon every iteration of the computer.

..

(5) The oxygen required to obtain the desired final carbon Cf can then be obtained by rearranging and integrating equation (15-3)

- ~

- _.-

-

R = ft~ = R (1 - exp [ -K (C - Co)]

dO P

(15-9)

Lance oxygen required

~-- ...

..

C f

._.__~~l~........__..~......_."..._____....... ~ de (15 -10)

R (1 -_ - exp [ -K (C - c )]

p 0

·!J.O c

-

-

c

•

A separate system for obtaining temperature was adopted.

Near the end of the blow, a weighted expendable thermocoupl~ was dropped into the upright, blowing furnace. The temperature measurement obtained could be used in an empirically derived equation to determine the end point temperature. In most cases a linear equation is adequate

(15-11)

. .... ....•. .. .... .

where T is the desired end point temperature, Tb is the measured expenda~le bomb thermocouple temperature, A is a process constant, the rise in temperature/unit of oxygen blown, 0T is the oxygeri-

which must be blown to get from the oxygen that had been blown when the bomb thermocouple trace was obtained to the oxygen required to supply the heat required to obtain the desired end point temperature.

The process computer compared the 0T and 0c values, and if ~c was greater- than 0T' det.e rmf.ned the amount of coolant which had to be added to reach both the carbon and temperature aims.

If 0T was greater than 0 , the initial concept was to take corrective action by raiSing the oxygen-±ance, decreasing the

decarburization,efficiency and burning more iron to iron oxide, thereby obtaining the temperature and carbon end points simultaneously. A second and more attainable strategy is to overblow for carbon in order to turn down at the desired end point temperature •

. ~

996

,

...

.. --

15-BOf Contlwl

I ..• t

Instrumentation for the control scheme was as accurate as possible to ensure reliable measurements of waste gas flow and

waste gas composition and process inputs. A good, predictive static model was also required so that the process would be close enough to the aim end points near the end of the oxygen blow so that only minor corrective actions would be required.

..... -.. .

..... - ..

..

III

During and after the development work on the dynamic control model described above, owher~~n the coefficients of the exponential decarburization curve were established during the course of a

particular heat, other attempts at control of carbon and temperature were being made utilizing off-gas analysis. Most of

these d~y~lopments were simplified versions where it was assumed that for constant blowing conditions the decarburization efficiency characteristic curve would be reproducible or predictab!eJrom

heat to heat. Early work utilizing infrared waste-"gas analyzers by Blum, et a1 (37) postulated a consistent decarburization rate curve from heat to heat. An analog computer was used to calculate the

. ,

function.

. ,

..

, ~.

. -r-

Leitzke and Schroeder (38) reported on a technique used by

several investigators, that of using the o~gen content of the

waste gas as an indication of bath carbon. The underlying assump~ion is that, if the decarburization rate is a function of carbon in the bath and if the waste gas exhaust system.removes th~ same amount of waste gas from heat to heat, the amount of air drawn into the hood to burn the carbon monoxide to carbon dioxide in the hood is always the same and the amount of oxygen remaining in the hood is then always the same for a given bath carbon. Variations

of this method would include direct observation of the percentage

., of-' carbon·diox'ide-"oin·-·t·her·was'te---gasc···-t·o ·'-estimate··bath-·'·carbon, and

observation of either a hood waste gas temperature or measurement of the heat load or strain on an oxygen lance to follow the course

•

of the decarburization reaction.

•

-

Papers by Shimata, et al (36) and Iwao, et al (39) have discussed the various decarburization models employed throughout the world. Again, most are simplified models of the actual process. There is work proceeding in Europe using the decarburization efficiency models and utilizing time of flight mass spectrometers to analyze the components of the waste gas. The work is in its early stages and has not progressed beyond using a single decarburization reaction.

Limi~~tions 2~.Gas ~~lysi~ ~etho~~

Gas analysis methods may be limited by any combination of the factors of instrumentation and analysis error, sensor reliability

997

..

_..

_r

'..._,. ----. -

............

..... p ••

Instrumentation and analysiS errors are the most basic and readily account for the poor accuracy achieved by the carbon integration method. Small errors in waste gas volume, density,

and analysis are cumulative and lead to very large. errors in carbon end point when integrated over a heat from ignition to turndown.

. .

--

BOF S.te.ehna.lU..ng

..

. .

• _.. • I

~ .... . .

and time constants~ process factors, and errors in the basic asslmptions on which the process scheme is based.

1

In the decarburization efficiency models~ whether they unilize a single curve or attempt to solve for exponential coefficients during a heat, there are.limitations brought about by the shape of the decarburization curve. The exponential decay equation cannot

be used to solve for carbon until after the instantaneous decarburization efficiency (R of equation (15-3» starts to decrease from the..... maximulD value of Rp. Assuming instant recognition and analysis of this break point in the exponential, there is only a limited amount of time available to calculate- carbon and to make

- .-.....,...._ .. --

a process correction if one is required. _ .

J

..

... t

The situation is further complicated by the fact that the break occurs late in the ~eat and it is obviously impossible to make a high cazbon afm, If the break point should be at a higher carbon than the aim, the time available to make a correction is a function of the specific blowing-rate, and the difference between the break point carbon and the. aim even with no ·system lag. From

Figure 15-6, if the break point occurs at 0.50% carbon with a specific blowing rate of 110 standard cubic feet of oxygen. per minute per ton· and the ajm carbon is 0.30% carbon, only 0.8 minutes is available to make a process correction even if the

recognition and computation time is zero.

,

. ". ~

- .' ,

Tj"me of flight mass spectrometers in place of the slow time

.. -.--~--.- =-cons tant; -inf zaned -and --thermal--·conduc t-i vi ty-anal-yze-rs--h-ave -been -.. ..

used in an effort to improve the overall tjme constant of a waste gas analYSis system. However, there still remains some system lag

(which can amount to 10-15 seconds) between an event in the furnace

and the analysis of the gas. This lag is a function of bot.h the

transport time for the gas to reach a spot where a representative sample can be obtained and the time required to sample, clean and condition the gas for the spectrometer or other analysis instrument.

-......_____

--..

•

Another factor which enters the picture and limits the usefulness of gas analysis techniques is the nature of the information that is being generated every time increment of the process. In theory, the exponential is monotonically decreasing and the

last piece of information received can be used to calculate for carbon and oxygen. In practice, there is considerable variation and noise in the interval-to-interval information received. Figure 15-2·il1ustrates this. Instead of monotonically decrea~Ingt

998

..

r., • I P. •• •

...

_ ..

..

2

..

...

15-BOf Contlwl

1

..

10

-

, .

9

8

"]

IlO,JIHG irATE. scf""ton

... " ...

•

.s 6 E

75

..

. ' .... ---.

3

-

.....

o~~~~~~~----~----~~--~~~~~~~~~

O~OO 0.10 0_20 O.XI ·0.«1 0.50

IA1H CARBON, %

0.60

Q.70

-".

. .. -

'I ... 1_' I •

. - .

Fig. 15-6:-· ·Time Available for Corrective Action

(After Kerns and Stelts12)

..

. ,

.. I _.. _ ...

- . ~ ,- .-

-"

- - ........... -1'. .

.. . - .

•

R may increase for short periods of time during the latter period of the blow and therefore a considerable amount of data smoothing is necessary to obtain a function which can be analyzed with some confidence. (Note that the rate R in Figure 15-1 has bad considerable smoothing on it as presented. Each value of R is a weighted

moving average of seven instantaneous values obtained over 14 seconds.) The time constant associated with data smoothing plus gas sample transport leads to a theoretical upper limit of control of about 0.15% carbon for gas analysis techniques. In actual

p_~a.<::~:j..~.~,. tl!,~ .... ~O~~~9.l._. ~qy .. -Q_~.app.l_;:l.~~J~-l:~ -Q~1~Y 'i;(). sbeat .g~~g~s.

..

. '

, . ~. .

•

. . -

Another factor which has militated against the success of gas analysis . techniques for carbon and temperature control has been the fact that the decarburization efficiency curve ha& not been a true exponential decay, but only an approximation. At each computer

iteration, the values of the constants Rand K change, and they too must be smoothed and averaged. However, even when this is done,

changing values of the constants lead to poor predictions of the oxygen required for decarburization.

..

The basic problem in utilizing waste gas analysis for close control of carbon lies in the scheme's basic assumption, that the decarburization efficiency is a direct function of the carbon in the bath for anyone heat. (Figure 15-5 has already been used to show that the decarburization efficiency is not related to carbon for all heats. This also indicates that processes utilizing any one waste gas component; such as oxygen .. or carbon dfoxf.de or f l ame

.-- _......_

999

•

- - • • ~ • --... .. - -If' -

. ~ .... -,.. ......

•

so F S.te..e1.ma.king

...

.. :. . ..

.. -

I I

radiation cannot hope to yield more than an approximation to the bath carbon and are not suitable for the close process control required for most modern quality-oriented steel products.) The results

obtained with dynamic control indicate that ~ecarburization efficiency can only be used to approxjmate bath carbon,- even on a single heat basis and with all other known process inputs constant. Other complex unknown factors such as the amount of foam (40) and emulsion present at any carbon level also· affect the decarburization. The stability of an emulsion and the amount of metal present in the slag phase can .strongly affect the decarburization rate~

and the influence of these items cannot be deterulined or calculat-

ed at this time.. ~. , -

.. ":. . r" ... ..... . +

,

.

~ )

' •• ~ •• _ .;~ r r •

. I

.+

I

•

•

In summary, gas analysis and dynamic control methods have proven inadequate for control of heats with aim carbon greater

~- -

than 0.15%. For low carbon heats, the control is not outstand-

ing because the assumption that the decarburization efficiency is a function of the bath carbon alone is not correct. Temperature measurement by bo~b thermocouple is feasible, but the cost per reading is excessive and has been replaced by other methods of

temperature control.

•

... .

- ... _........ ...

•

SENSOR LANCE CONTROL

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In earlier sections the limitations of the static model approach have been discussed. The unpredictable random heat to heat variation in the decarburization and slagmaking reactions have resulted in considerable deviations from the aims in carbon and temperature at turndown. Also, the failure of indirect methods

such as flame radiation and gas analysis to control bath carbon has been discussed. Flame radiation, in attempting to correlate flame inten~ity characteristics which are related to the burning. of carbon

. - " .. ' '--_ - _. --- -- ------ ------_-- .. _ - .. '-"_ ---- - --. ._ -- -----------_._.. -- - -- --- - _. __ _'--_. - .. _-_-. - - ._- ,'_ - _ _. - . .-- - - _-_. - -------_._--_. ._ - -- .. .- - _.. - .. _.._ _." -_._'" . __ ---._-----_. -- .. -- ----- --'.' .-. - .. . .. ,.,,' . .

monoxide in the hood and which in turn is vaguely correlated with

the bath carbon, is an indirect method of control twice removed from the·variable which is to be controlled. Gas analysis techniques by the same rea.soning are once removed .. from the variable to be controlled.

,

As these earlier attempts at control were shown to be un-

satisfactory, efforts were concentrated on directly measuring the carbon and temperature in the furnace with only a minimal amount of process interrupt. Workers in Europe, Japan and the United States all utilized secondary lances to permit carbon and

temperature measurements in the BOF (10-15). The approach has been either to obtain a continuous temperature measurement (10) or spot temperatures and/or carbons (12-15).

1000·

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15-BOF ContJLol

Continous TemEerature Measuring Lance

In 1969, Eibl and Trappe (10) reported on the use of a cermet protected thermocouple for the continous measurement of temperature in the furnace during the blow. The thermocouple was inserted into the bath using a water cooled lance after the forl1lation of a liquid slag and a temperature trace was obtained during the last 75% of the oxygen blow. The cermet tip, under proper conditions can last ten to fifteen heats before replacement. The device was initially

developed on a five ton BOF and then installed on a fifty ton

.

operating converter. The lance .system has sjnce been installed

~--.......

elsewhere on larger BOFs. - -

Intermittent Sensor Lances

Sensor lance development (11, 12, 41) at Bethlehem Steel has been reported.through several stages over a number of years. This lance incorporates automatic feed of devices and obtains high speed measurements of both carbon and temperature for control purposes from an upright BOF with a minimal interruption to the oxygen blow •

•

The pro-cesses for using a sensor lance and a blow interrupt - for control purposes evolved from two developments. The first of these was the control practice which had developed for making high

- . .- - ....,._.. _ ..• - ...... .... .

carbon heats on a catch carbon basis and which had evolved from

.

European two slag practice, wherein carbon and temperature could be

controlled very closely during the secQn4_blowing period because

of turndown and sampling after the first blowing period. In single slag heats, the practice consisted of aiming to turn down high in carbon (.20-.30% higher than ajm) and high in temperature, taking a standard sample for. composition, obtaining a temperature, and then reb lowing - and.ieoo.Ldng. to ",mee t -the ,-f-inal ..... aj ms., .This .p'ract Lce yielded the best results in terms of product quality and cleanliness, mini-

mization of ferroal1oy usage, and temperature and carbon control.

The corrections required with the short second blowing period were small and even with norD~l variations in decarburization efficiencies, the ajrns could be accurately attained. However, the time required

~

to calm the fu rnace slag, turn the fur nace down for sampling, and

obtain a standard composition sample and a temperature was excessive. The second development, which decreased the time required to obtain the percentage carbon in the bath, was the introduction of the disposable liquidus temperature cup for carbon. After a sample was taken by standard means, it was poured directly into the liquidus

cup and, as the sample s t.ar tred+t;c solidify, the plateau in the time temperature trace served to indicate bath carbon. This method sp-eeded the reblow pr cceas , bu t the time required to turn down and sample was still excessive for- regular operation at all carbon

grades. -~.

From this point, it was decided to develop a device which could be used directly in the furnace. Af ter the,_ e?CRsrimentation

.. -

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1001

-

r i - .,

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with drop-jn .expendable devices, attention was directed to a secondary lance approach utilizing a combined carbon and temperature sensor in an upright BOF. Earlier Fradeneck (11) and

others had developed an automatic experimental lance for standard end of blow sampling from an upright furnace. This lance had an automatic feed feature and its magazine could be loaded with thermocouples, samplers, or thermocouples an4 samplers alternately. Although this lance was not suitable for automat~c feed of

the original handbuilt, liquidus carbon and temperature sensors (12)

which were to be used to test the control concept, it was visualized that both a large and.rmo re rugged sensor lance that would have the multiple feed concept and a cylindrical cardboard-protected sensor could be developed.

. 1 I

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l

)

,

In the initial test, the experimental sequence was:

1. The charge materials and aim oxygen were calculated with the static charge model.

...

2. A liquidus carbon and temperature sensor was loaded into the sensor lance before the blow was started. An air cooled shield was placed over the sensor to protect it from flames and sparking •

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3. The blow was interrupted after 80-90 percent of the aim oxygen volume had been blown •

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4. The shield was removed and the lance lowered into the

furnace to a predetermined depth. ._. _,.

5. The lance was withdrawn after a bath temperature and sample had been obtained •

•

, .

. -- .. ----. ---- -._--.- -----6--; .--- ·--The·--i:±quidus~·-thermal - arres t-was -·-ob taine-d---a-s---·-t-he- -Lance was withdrawn.

, .

7. The oxygen vo Lume required to meet 'the aim carbon and the predicted temperature rise therefrom were obtained from the empirically derived average decarburization·efficiency and temperature rise curves.

8. The oxygen volume and the coolant ~equired were

t ransmf.t t ed to the operator and the blow resulned with the new oxygen and coolant aims.

Control tests with tn1s--·experj-mental arrangement demonstrated that:

•

Carbon and temperature could be controlled to a much closer level than with the static model at all steel carbon levels.

The steel clad carbon and temperature devices, developed after much ex·perimental and pilot scale work, were reliable and

1002

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of' •

15-BOF CoYLtltol

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accurate, but were also expensive and ill suited to magazine feed.

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• For optim1$ sensor lance operation the installation should have

high speed raising and lowering, operation independent of either oxygen lance, magazine feeding of cylindrieal devices and all controls except magazine loading should be located in_ the operat-

•

ing pu Lp Lt ,

-

· .

The sensor lance development then proceeded at two locations.

- -

At the original experimental location on a 280 ton BOF, the

.

experjmental lance was replaced with a larger, but still ~low

speed, version. Cylindrical cardboard-protected sensors could

be loaded onto the end of this .. lance and then could be retracted into the lance body so that the sensor could be protected while the lance entered the furnace during the blow interrupt tests. Once the operating depth in the furnace was achieved, the device could be extended from the lance into the steel bath. -This facil~ ity was to be used for development and testing of cardboardprotected sensors. The second development was the installation of an operation automatic sensor lance in a 270 ton furnace at the Bethlehem, Pennsylvania (41) plant.

The sensor lance control system was designed to have all the desirable features nent.Loned above. In addition, the .design provided for:

• Compensating for normal dimensional variations of c~rdboard-

protected sensors caused by temperature and humidity changes.

• Protecting cardboard sensors while the lance is over the

furnace and while the lance lowers the sensor to the test position.

•

. .... - ._.

•

Feeding of sensors automatically.

..

i ...

• Protecting the lance tip to permit lowering into high foamy

slags.

· Protecting the electrical contacts for the thermocouple

signals.

The completed lance installation has been in use since late

...

1970. The procedure followed is similar to that developed during

the experimental stages. The more robust construction of the operating lance, its speed, and the ability to eject a second

,

sensor if either the bath temperature or the liquidus temperature

thermocouple fails on the first sensor are the main differences from the experimental lances. The sensor Lance can be lowered

•

while the oxygen lance is still blowing. After completion of the

90% oxygen blow, and as the oxygen lance retracts automatically, the

1003

. _. - - - --

I

Tables I and II illustrate the control and the turndown performance

" -

compared to a static model practice.

making carbon heats:

degree of carbon and temperature attained using this practice There are three strategies for

BOF steeima.h..i..ng

f

,

sensor eject button is pushed and a sensor enters the bath. After

a preset time (5 seconds), the bath temperature is measured and the sensor lance retracts automatically. (In case of sensor failure, the automatic lance retraction can be stopped and returned to the sampling position.) The liquidus trace is generated as the sensor lance retracts. The oxygen blow can be resumed, the interrupt

carbon and temperature read into the computer, and the corrected oxygen and carbon aims generated.

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Catch carbon, charging and blowing to turndown at the aims.

_. _...............

· Overblowing until the heats are flat and hot and then

recarburizing and cooling.

• Planned reblowing, aiming to bring heats in hot and high in

carbon and then reblowing and/or cooling to the aims.

-...- ...

...

, .

TABLE 15~1

..... .

SUMMARY OF CARBON AND TEMPERATURE CONTROL - SENSOR

LANCE CONTROL VERSUS STATIC MODEL_ PRACTICE

Deviation from Aim TurndoWn Level - 95% Confidence

•

Aim Carbon ~nge

Sensor Lance Control

Static Model Practice

O.ll~O. 20% C"

+0.078% C

+0.120% C

0.21% C and above

+0.111% C

+0.205% C

-

•

All

+38 F

+70F

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15-BOF Contltol

-------

TABLE 15._2

COMPARISON OF LANCE SENSOR -CONTROL VERSUS STATIC MODEL PRACTICE

Seusor Lance Control

Static Model Control

% RSblown

15.0

16.4

% Cooled

20.7

33.6

% Reblown and Cooled

2.1

18.7

•

% Ready To Tap

L •• _. _ " 62 • 2

31.3

The development resulted iri a 1.4 minute-saving in average heat time over standard practice.

Sub~lance Control

Other sensor (or sub-lances) lances that have reported results

, ""

in ~he-literature have been concentrated in Japan. Nagano, et al

(13) have reported on the use of a single shot lance to measure

.

temperature or take a sample in the Tobata works of Nippon Steel.

Tsuzuki, "et a1 (14) have reported on a sensor lance using a single

--, -sno~---expelitlaDlEf-tnertfioc-Olitil'e-- durLng" 'the' '. oxygen "-'-b low'- -at·",,· the Muroran

works of Nippon Steel. The Keihin (15) works of Nippon Kokan KK

have qtilized a carbon and temperature sensor utilizing a single shot

lance· for obtaining a tapping sample at the end of the blow. If the measured carbon and temperature are correct, the heat.is tapped without tilting for sampling. Further installations have been incorporated recently in new BOF shops. The degree of automation and control

has progressed much faster in Japan than in the United States in recent years.

Examples of Japanese BOP Steelm~king progress in control have been illustrated in papers by Hayashi (42), Kaga, et al (43) and Miyoshi, et al (44). The trend has been to automatic control of the process from initial calculation of the charge, through flux additions,- in-blow sampling for carbon and temperature corrective action, to end-hlow sampling. The time savings and productivity gains have

been substantial. Hayashi (42) has described the system at Nagoya

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which is typical of recent Ntppon Steel installations. The sub-lance utilizes an external feed cardboard probe which is mounted automatically by a sophisticated probe changer and then is inserted in

the furnace during the oxygen blow about two minutes before the estimated end of the blow. The device measures liquidus carbon and bath temperature. The temperature traces are read by the process control computer, corrective action is undertaken automatically, a sample is retrieved from the in-blow test and sent to the chemical laboratory where it is analyzed for sulfur and phosphorus. If the residuals are within range and the heat is a non-critical grade, it may be tapped immediately after the oxygen lance is withdrawn.

If the heat is a critical -:sraae, an end blow test at oxygen off is taken and sent to the laboratory. Utilizing this technique, the

Nagoya works has about 90% of its heats ready to tap at first turndown. The tjme from oxygen off to start tap is in the range of 2-4

minutes compared to a range of 8-18 minutes for other control practices. The standard devfaca.on .. _i,n. end blow temperature is ±11° F. For heats with a carbon aim above .09%, the standard deviation in aim carbon has been reduced to ±.012%. These results are the best achieved to date in the field.

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Limitations of ~~~~ndary La~~~_C~~t~o!

J

There are two main limitations to the use of. sensor lances

for process control, engineering difficulties and capital costs based on incorporating a sensor lance in a shop where the hood was not designed for a third lance, and process limitations. The engineering difficulties and capital costs· of an installation have slowed the development of these processes, but as new shops are

being built around the world, they have tended to utilize this method of ~ontrol. Process Ijmitations are being attacked. The

. _ -- .. - ------- - .--_ thr e_e _ma.in-_.limiting .. .areas.ifor a _p_ro_cess _int er rupr. __ me.as urement ... are error due ~o the liquidus carbon and bath temperature measurement, subsequent errors in carbon due to the variation in decarburiza-

tion ef.ficiency during the Las t blowing period, and errors in temperature attributable to variable rates of temperature rise per increment of lance oxygen.

Measurement errors may be due to the sampling device or to variations in bath composition and temperature throughout the bath. This second possibility has been explored at Bethlehem and elsewhere utilizing mUltiple sensors at different times after the oxygen has been turned off and specially made sensors at dif-

ferent bath depths. No contribution to overall system error could be attributed to bath segregation~

+

The accuracy of the sensor measurement can contribute error

- -

to the system. In the VOEST (10) system, the bulk of the cermet

protection tube leads to temperature lag be~ween the bath and the thermocouple and may decrease the advantages that would accrue

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1006

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15-BOF Con:tltoi

to a continuous measurement. On the other hand» the accuracy of

the single point thermocouple is good, but the single point measurement does not y~eld any indication of rate of temperature rise and if an average rate of rise per unit of oxygen is used, this can lead to errors •

•

Carbon measurement error in the liquidus device can be a problem. The accuracy of the device when used in-furnace has not approached' that of the standard method where the cup is used on the charging floor and a well-killed slag-free sample is poured into

it. The in-furnace sensor relies ana cap to keep out slag and the results are not consistent~ ~lose quality control is essential.

Liquidus thermocouple placement is critical and if the thermocouple is off center or does not emerge far enough from the base

of the in-furnace sampler variable liquidus traces are. obtained.

The characteristic decarburization curve does tend to minimize the error due to a poor liquidus carbon measurement. Although a 0.01% error in carbon at an interrupt of 0.60% carbon results in a·O.Ol% error at 0.45% carbon, the error is reduced to 0.005% at 0.15% carbon and 0.001% at·O.05% carbon. However, as the length of time from the interrupt or in-blow test increases, the error due to the assumption of an avera_ge decarburizatioll efficiency also increases. To minimize this error, it is desirable to have the secondary lance test as close to the estjmated endpoint as is possible without overshooting.This point is a function of the static model accur~cy.

A more accurate static model would lead to an interrupt close to

the aim and if it were attained through reproducible blowing conditions, the accuracy of the carbon and temperature control would then tend to appnoach the accuracy of the sensor, ~hich can be improved through care in assembly and good quality control.

In snnnnary, after the failure of systems which attempted to -co rrela te,.second-·--and .. ···t hi-rd· _ - ordar --e f £e-Gt s _- tio-ba th,_-·ca-rbon -and _

...

temperature, there has been a move to direct measurement of the in-furnace variables. This has led to improved control, but the costs and engineering difficulties associated with incorporation

--

in an existing shop has slowed the spread of these techniques.

However, the results attained with secondary lance control in Japan have demonstrated the substantial gains in productivity and lowered costs which can be attained.

BLOWING CONTROL METHODS

.

The use of Thomas iron in Europe with its high phosphorus

content and attendant high slag volumes -bas··been cited as one of the incentives for blowing control. In the United States recent

~ -

interest in blowing control has been precipitated by the demand

for more stringent product requirements at the same time as the quality of the hot metal has deteriorated because of· the use of highe~sulfur coke in the blast furnace than had been the practice

• ill +

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1007

...

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,

in earlier years. The product demands have led to higher slag burdens in the BOF. The situation bas also been aggravated throughout the world by the seemingly irresistable urge to increase charge weights (thereby decreasing furnace volume per ton of steel) up to the limits of the teeming cr anes; With

. higher charge weights and slag burdens in a given furnace volume, excessive slopping occurs with resultant lower product yields, higher rubble pit maintenance, and poorer control of steel phosphorus and sulfur residuals than heretofore •

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The most common type of blowing control in basic iron practice has been operator observation of the furnace. If a heat becomes

to wild and sloppy, appropriate action is taken on the lance

height or oxygen rate. Usually this action takes the form of decreasing the lance height, decreasing the oxygen rate significantly, or decreasing oxygen rate and lance height together. In large furIlaces, the amount the lance height must be decreased in order

..

to affect a change in slopping behavior is significant and the

more conman corrective method seems to be to decrease the oxygen

. .

rate, and perhaps the lance height, in order to.decrease the amount

of gas leaving the furnace. For the opposite effect, large quantities of spar m?y be added to the furnace, and the lance

height purposely kept high to obtain a very fluid reactive slag, to obtain low phosphorus residuals, and to fill the furnace with foaming slag which minjmizes air aspiration and maintains a low nitrogen

residual. . . ...

..

I

,
......
4
. .
f -- ..

Aukrust, et a1. (20) have described a loop for blowing control which was to be used for control of the early staRes of decarburization. The decarburization efficiency parameter was monf.coced and when it deviated from a given track, the lance height or the oxygen rate was to be altered in order to bring the parameter into a

. _contro_l __ ban.d~ __ T_be system never saw extensive use. The instrumenta-

. --.-- . __ .. _--- ----_.- - - . --------_. - -_.- - ----------_.- -._------ __ .......___ ---_ . ._ .. --_._-- ._-_ .. __ .- .. _.

tion time lag was such that slopping was detected by the operator

who saw sla~ coming out of the converter before the instrumentation observed the change in the decarburization efficiency. A more serious problem was that the. indication of incipient s Lopp Ing, __ a decrease in the decarburization efficiency, was difficult to

detect in real time. The normal variation in process noise during a heat (Figure 15-1) was such that a dip due to slopping was difficult to detect •

. .

..

· . .

..

Later at cempcs using jmproved instrumentation have been reported and are discussed below. The systems are similar in many aspects and as of the last reports were either experimental on one converter or had been examined in a plant trial and were to be incorporated into the shop on a more 'permanent basis.

Work reported by Rossner~ et al. (21) discussed three ton pilot studies done from 1964 to 1967 and the system installed since 1967

1008

.......

15-80f ContJtOi

' .. r: '. ~

"'I._.. _

on a 100 ton BOF. There are two control loops~ one to control the oxygen distribut~on ratio betw~en the slag and bath and another to control the waste gas heat flow. Process data are monitored using a digital computer. In addition to the process function and the computed quantities 0 and 0 , the noise generated during the process and the slag gonductIvity were also continuously measured.Waste gas analysis using a time of flight spectrometer was utilized and gas volume measured across a venturi meter; 0c was defined as that portion of the lance oxygen which reacts per unit with the carbon in the bath:

- -

o

dt

(15-12)

I

o c

pis:: .....

_ _.-.-"

where dOB/dt is the lance oxygen-flow rate and dOc/dt is the amount

__. --.-._. ---

of oxygen-reacting with ,carbon per unit time. _ .

... - _ ...

..

' .

From the waste gas analysis in the hood system:

. ~ .

:- .• ·IIt .'

~ .

..

. .

dOc

Lz4T" .... =

dt

(15-13)

where CO, CO2, 02 and N2 are the measured components in t~e waste

gas volume V. ~1S the amount of chemical reaction heat plus sensible

heat leaving in the BOF waste gas system per unit time

(15-14)

-

... _ ___.......

I_~II

a is the heat of the reaction CO + 1/2 02 ~. C02

band c are the sensible heats of CO and CO2, respectively

-

After preliminary tests had established the suitability of the sampling equipment of the installation, data logging tests were

run on a number of non-controlled heats to obtain correlations be-

•

tween lance height, oxygen flow ~ and 0c that would be used in

control strategies. Within control limits the calculated variables

.

wer~·adjusted by adjusting lance height, oxygen rate,' or-lance height

and oxygen rate. Control experiments were run on both Thomas and basic iron. Some degree of control of the heat output, Qw' and the

1009

...

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BOf steef.ma.tung

oxygen distribution, 0 was obtained in the tests and work was to

. . c:

cont.anue on defining an optimum value of 0 • c

•

I

Blowing .Con~rql_ Us.!!!s F~_e T~Eer!ltu.Fe I an:d ,SO~<:l., Level ~e,asurements

Centre Recherches Metallurgiques (ffiM) has worked extensive- - lyon noise measurements for slag formation con~rol.The early work of .Parsons and Shewring (16) was done in cooperation with CRM. More recently, CRM has attempted to control the decarburization trajectory in a~ effort to improve their static model calculation for end point control of carbon and temper-ature". They have reported extensivelyon blowing control developed on a pilot converter and have installed a developemental analog computer at Seraing (19, 45, 46, 47, 48) on two 180 ton BOFs utlizing both a noise analysis (acoustic)

meter and waste gas temperature measurements-for process measurements. Through their research they have established that the partition of

•

oxygen bel~een bath carbon and slag dur~ng the first portion of the

oxygen blow is of importance in obtaining reproducible blowing conditions without slopping and ftrrnace ejections.

The decarburization rate must increase steadily at a rate governed by the slagmaking and lime dissolution characteristics of the operation. The flme temperature measurements in full

. combustion hoods are related to the decarburization of the bath and are used to control the decarburization zate, The slag

oxidation state is det.ermfned by acoustic measurements. CRM have used their extensive background i~ this technique to establish suitable frequencies for a given shpp and, by off-line analysis of data, have determined which characteristic curves are related to excessive slag oxidation, slopping and poor temperature and carbon control. During maximum decarburization in the BOF blow, there is a little danger of slopping if the initial steps have been

.. - - - - -- - - - - - ---co rre ct: 1 y --con t rolled-. ------------------ -- ---- --- --- -~ - -- -- - ---- --:- - ---- ------- ---- - ----- ----- --- -- - ---- - -- - --

In the third stage of the blow, the decreasing decarburization efficiency_is then claimed to have a somewhat closer relation to bath carbon than'is usually the case if the initial_decarburization and slagmaking trajectories are not controlled.

,

The mo~t suitable acoustic frequency for controlling slag

oxidation in a BOF is found by trial and er~or. The advantages of the thermocouple for inferring decarburization rates is its fast response to process changes when compared to infrared gas analyzers.

Lance position is controlled by a predetermined program. Once

• • ~r

the lance. height reaches its operating position, it is not raised

unless the aco11stic measurement indicates insufficient slag oxidation. Changes in both decarburization rate and slag. formation are accomplished by manipulating oxygen flow and lance height.

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The oxygen flow rate is altered so that the temperature, (the decarburization rate) will follow a given curve. (This curve is not the decarburization efficiency curve described in waste gas analysis, but rather is the decarburization rate per unit time. The two are only equivalent if the lance oxygen rate is· never altered.)

Limitations of Blowing Control

To date blowing control has only been applied on a very

limited basis and all the installations discussed have been experimental. The instal1ation·at Seraing was to be converted from an experimental analog control .to a permanent digital installation. The results on the permanent system have not been reported.

" -

Blowing control has been worked on extensively and, aside from

operator guided control, little is known as to its effectiveness. The fume temperature-acou·stic measurement technique in combination with a static model has made some improvement in the predictability

of the model and in the reproducibility of the slag composition generated during the oxygen blow.

--~"I'

CONCLUSIONS

Most of the BOF production in the world is still controlled by

the operator using the basic tool of flame drop, perhaps augmented by a slide rule or set of charge tables. The techniques outlined above give better results ~han simple operator control and are being implemented more and more widely as newer BOF shops are built

to make products to more anc more str~ngent limits.

- No e.f for t; has been made. to. include. all the wo.rk in .BOF control over the last fifteen years and only the major areas have been covered. Of these areas, the basic static model is still the most

.....

widely used control tool. Early attempts at gas analysis were un-

successful in achieving good control at less than 0.15% carbon and could not be used with any-condidence above 0.15% carbon. However, development is still proceeding in· this area. Sensor or sublances, in connection with a good static model, can control carbon and temperature at any level and are rapidly finding favor in spite of their high initial cost. This technique has yielded the best carbon and temperature control, fastest oxygen-off to tap times

and greatest productivity gains of any control technique developed

to date. ·

..

Blowing control has been worked on extensively but aside from operator-guided control, little is known as to the full capability_ Blow~ng control in conjunction with a soundly conceived static model appears to be a promising avenue where operating costs might be cut, not only ··by carbon and temperature control, but by savings

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in fluxes charged to meet product ~ims, but will probably not achieve much progress towards, the goal of all heats ready to

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REFERENCES

.

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1. Foundry Trade, 61, (1940), 104 and 181 .

':b 2!!!iiIIII

2. G. Naeser and H. Krachter, Stahl und Eisen, 62, (1942), 341.

~ .... - ---

3. F. J. MCMulkin, Open Hearth Proceedings, AIME, 38, (1955), 251-254.

4. w. O. Philbrook, Open Hearth Proceedings, ~UME, 41, (1958), 382 ... 398.

--

-

5. w. J. Slatosky, Trans. Met. Soc. ArME, 221, (1961), 118-130 •

• L ::-. LIi

6. K. Katsura, K. Isobe and J. Itaoka, Journal of Metals, April 1964, 340-345.

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8. J. Dumont-FilIon, F. Mangin, C. Bachet and H. Pierrand, Rev. de Met, February (1963), 105-113 .

...

..

.

... .

9. H. W. Meyer and J. A. Glasgow, Iron and Steel Engineer, 4~ (1966) 526-532 •

......-----.-- . - ~ --- - -- . ..__...._

10.

J. Eibl and M. Trappe, BHM, 114, (~969), 390-396, Translation

.. ....

BISI 8529.

---- ... _.--

11. R. J. Fradeneck, U.S. Patent 3,327,531.

12. D. w. Kern and P. D. Stelts, Iron and Steel Engineer, 45
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.. . .. - - . . . - - _.- . . - .. ~ -
13. Y. Nagano et aI, Tetsu to Hagane, 56, (1970) , 807-812,
--
Translation BISI 10263.
<II .... 14. s. Tsuzuki et aI, Tetsu to Hagane, 58, (1972), 151-157, Translation BIS! 11301.

15. N. Nagaoka et al, Proceedings ICSTIS, Section 2, Supple Trans.

ISIJ, Vol. 2, 1971, 351-354.

16. A. E. Parsons and D. Shewring, JISI 202, (196~), 401-405.

v

--- .......................... -

17. J. Maatsch, U.S. Patent 3,396.960 .

•

18. F. Bardenheuer and P. G. Oberhauser, Stahl und Eisen, 90, (1970), 789-795.

~

1013

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t

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19. P. E. Nilles and R. A. Halper, Open Hearth Proceedings, ArME, 55 (1972) 94-107.

20. E. Aukrust, M. M. Fischer and W. F. Porter, Symposium on Continuous Processing and Process Control, Philadelphia, Pa • December 5-8, 1966, Met. Soc. Conferences 49, 343-366.

21. H. Rossner, B. Reinhold and G. Urban, Iron and Steel Engineer, 47 (1970), 70-76.

22. G. W. Healy and D. M~Bride,. This Volume, Chapter 13.

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24. w. J. Slatosky, JIS!, 200,(1962), 37-40.

25.- T. R. Linde, Unpublished Work, Bethlehem Steel Corp.

26. D. G. Boltz, Iron and Steel Engineer, 44, (1967), 117-124.

...... F

27. P. Dauby, M. Bach, P. Hoffman and P. Nilles, CRM Metallurgical Reports, July, (1968), 33-44.

28. J. Pivont, G. Dehalu, J. Pauwen, P. Nilles, P. Dauby, N. Bach and J. M. Fischer, CRM Metallurgical Reports, July (1968),

45-- 55 • ~ - - ~.~. --.-,.~

29. M. M. Fischer, 17 Annual Instrument-Automation Conference,

.....- - +- .. -

ISA Annu~l Conference, New York (October 15-18, 1962).

30. P. Booster, Steel Times, January (1965), 82-87.

a,

31. H. W. Meyer, D. A. Dukelow and M. M. Fischer, IRSID -

International Congress on Oxygen Steelmaking~ Le Touquet-_

Dunkerque, Sept. 23-26-, (1963), 1-10.

32. D. W. Kern and D. G. Boltz, Unpublished Work - Bethlehem Steel Corp.

33. J. D. Fillon, u.s. Patent 3,181.343.

~

34. D. A. Dukelow, W. F. Simcic and C. R. Thomas, Iron and Steel Engineer 41 (1964) 785-789.

35 • W. E • Dennis, T. G. J elm-and W. F. Porter, Rev. de Met., 66, (1969), 519-526.

•

36. M. Shimata, S. Ohishi, N. Iwao, K. Naito, M. IvIaeda, Yawata Technical Reports, 266, March (1969), 8917-8958~

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37. B. B'Lum, J. W. Schwartzenberg and F. C. Luxl, Iron and Steel Engineer, 44, (1967), 111-119.

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38. V. A. Leitzke and D. L. Schroeder, Iron and Steel Engineer, 44, (1967), 121-129.

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~, .

39. N. Iwao, Y. Nagano, M. Maeda and S. Yamamoto, Nippon Steel Technical Report Overseas, No.1, August (1972), 78-98.

40. H. W. Meyer, W. F. Porter, G. C. Smith and J. Szekely, Journal of Metals, 20 (1968), 35-42.

- .... .. r ~

41. D. W. Kern, P. D. Stelts and R. J. Fradeneck~ Journal of Metals, 23, August 1971, 9-19.

42. S. Hayashi, Open Hearth-~rbceedings, ?~ (1976),102-112.

43. K. Koga, Y. Ohkita, M. ~tizutani, and A. Kwami, Ironmaking and Steelmaking, 3 (1976), 146-152.

-

44. S. Miyoshi, K. Taguchi, I. Tsuboi, J. Hasegawa, Conference on Contral of BOF Steelmaking, September 2-4, 1975,

Toronto, Canada.

. '-

. __ .. _ ..

45. P. Nilles and E. Denis, CRM Reports, June (1968), 81-86.

46. Y. Noel, R. Halper, J. Luckers, C. Stoltz, C. Van Den Hove, eRM Reports, June .(1968), 86-92.

47. G. - Dehalu, CRM Reports, June (196_$), 93-95.

-.-

_ ..

48. P. Nilles, E. Denis, F. Merker, P. Dauby, CRM Reports,

June -(1971) ,-3-10-. - - ----- -- - - - - - - - - - -

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1015

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