RECIRCULATION DEGASSING PROCESS

Principle
The principle of the recirculatory degassing process is as follows:-
A ladle of liquid steel is transferred by car or turntable to a position below the vacuum vessel.
The vacuum vessel is constructed from steel plate, and internally lined with refractory bricks. The
bricks are held at a high temperature by an oxygen-gas or electrical heating system. Two noles
or snorkels are attached to the lower part of the vacuum vessel. These noles are refractory
faced both internally and externally. !ne of the two noles is equipped with a number of small
bore pipes set in the internal brickwork.
To treat the liquid steel, the vessel is lowered, or the ladle raised, until the two noles are
immersed a predetermined depth below the surface of the liquid steel in the ladle. As the noles
are immersed in the liquid steel, an inert gas "normally argon# is blown at a controlled rate
through the small bore pipes in one of the two noles.
The vacuum vessel, which is connected to a set of powerful vacuum pumps, is then evacuated.
Atmospheric pressure, acting on the surface of the liquid steel in the ladle, forces two columns of
liquid steel up the two noles and into the hearth of the vacuum vessel.
A pressure differential of one atmosphere can in fact support a column of liquid steel
approximately $.% metres in height.
The in&ection of argon into the liquid steel in one nole produces a reduction in the bulk density
of the resultant liquid steel ' gas mixture. The effect is to raise the height of the liquid steel column
above this nole. As the gas is removed from the steel as it enters the vacuum vessel, the
column then collapses, and flows across the hearth of the vessel.
The main feature of the recirculation degassing process is the immersion of two noles, the up-
leg and the down-leg, into the liquid steel.
The steel is induced into the vacuum vessel by in&ecting argon into the up-leg. The dissolved
gases and argon are then released into the vacuum.
The degassed steel returns to the ladle via the down-leg. Alloying is carried out under vacuum
without the effect of a slag reaction.
The additions are made via a (-chamber vacuum lock of proven design. Temperature losses are
minimal due to the vacuum vessel being held at high temperatures between treatment.
Advantages:
)ationalisation of the primary melting production.
*ast vacuum carbon deoxidation reaction.
+acuum decarburisation to less than $, ppm -.
.o need to tap slag free.
/ndependent of ladle freeboard.
Achievement of narrow temperature and analysis ranges.
0igh recoveries of elements with large or small additions of alloying materials.
1ffective temperature and analysis homogenisation.
1xcellent separation of non-metallic inclusions
/n this way a continuous flow of liquid steel is produced from the ladle, into the vacuum vessel via
the nole equipped with argon pipes, normally called the up leg, through the vacuum vessel and
back to the ladle through the other nole, called the down leg.
+ery high rates of liquid steel recirculation can be achieved by this process, up to $23 tonnes per
minute or even higher.
The recirculation rate is dependent on the cross sectional area of the noles and the amount of
argon gas in&ected through the small bore pipes in the up leg.
The vacuum vessel is equipped with a vacuum lock, which allows additions to be automatically
weighed and batched externally, and then added to the steel inside the vacuum vessel without
disturbing the low pressure conditions in the vessel during treatment.
Process
The recirculatory process is used to treat liquid steel under vacuum for a number of metallurgical
and production reasons. The main reasons are as follows:-
0ydrogen removal
The presence of hydrogen in steel in even very small concentrations can cause sudden and
catastrophic failure.
0ydrogen can be removed from liquid steel by surface diffusion. This is achieved by creating a
vacuum above the liquid steel surface and generating sufficient movement of the liquid steel to
maximise the amount of surface area exposed to the vacuum.
The recirculatory degassing process is capable of reducing residual hydrogen contents down to
levels of $.3 to $., parts per million.
-arbon and oxygen removal
These two elements are linked, since, under vacuum carbon and oxygen both dissolved in the
liquid steel, react together to form carbon monoxide. The carbon monoxide is removed from the
liquid steel as a gaseous product, being pumped from the vacuum vessel by the vacuum pumping
system.
4hilst the reduction in dissolved oxygen in the liquid steel by this method can be quite significant,
it is not normally enough on its own to achieve acceptably low levels of residual oxygen.
The carbon-oxygen reaction under vacuum is more commonly used to produce ultra low carbon
steels for applications such as auto body sheet. +acuum decarburisation can reduce the carbon
level of the steel from initial levels of between 533 and %33 ppm down to less than $, ppm.
.itrogen removal
6ignificant removal of nitrogen during recirculatory degassing only takes place if both oxygen and
sulphur levels in the steel are already very low prior to degassing.
Alloying
7ecause alloy additions are made under vacuum into a slag free bath, recoveries are high and
consistent. This gives the operator much greater control of chemical composition, and the ability
to produce steel to very tight analytical ranges.
-leanness and homogeneity
6teel cleanness can be improved during recirculatory degassing by the agglomeration and
flotation of non-metallic inclusions. The high rate of liquid steel recirculation accelerates inclusion
collision and therefore agglomeration. 8arger non-metallic inclusions are removed more quickly
by floatation.
0omogenisation of the ladle contents both chemically and in terms of temperature is rapidly
achieved, again due to the high rate of recirculation.
Application
The recirculation process is used to produce a wide range of steels, including rail steels, plate
and section, structural, ball bearing, low carbon sheet, electrical and high alloy grades.
/t is particularly suitable for treating unkilled steels in the production of low and ultra low carbon
grades.
0ydrogen removal performance is good, making it suitable for the treatment of rail steels and
plate grades.
The recirculatory degassing process is also good for close analytical control, and for rapid
homogenisation of the ladle contents.
8adle sies for the recirculatory degassing process range from %, to %33 tonnes, although most
units are in the range of $33 tonne or more.
Advantages
The recirculatory degassing process is very adaptable, being suitable for hydrogen removal,
general analytical control and particularly suitable for the vacuum treatment of unkilled steels.
Temperature losses are relatively low, and there is no requirement for changes to the normal
tapping ladle or additional freeboards "i.e. reduced tap weights#.
9eslagging of the ladle before treatment is not required.
.o porous plugs required.
RECIRCULATION DEGASSER WIT O!"GEN #LOW $RD%&T#'(

The application of the conventional )9 process is enhanced by the fitting of a water cooled top
lance which can blow oxygen onto the circulating liquid steel. This development has a beneficial
effect on the converter operation.
Advantages:
All the features of the )9
:rocess.
+acuum decarburisation of higher
than normal tap carbon content.
Tap temperature can be lowered
due to a temperature gain during
the blowing phase in the vacuum
vessel.
:ost-combustion of -! to -!( in
the vacuum vessel giving thermal
and environmental benefits.
.o reduction in refractory performance
compared with normal )9 treatments.
There are no submerged oxygen noles.
0ence, there is no requirement for additional
inert gas in order to keep lance &ets open and
the capacity of the vacuum pumping system
can be kept on a moderate level. ;tility
consumption is minimised.
The possibility exists to produce stainless
steel.
/n the unlikely event of skull formation the
possibility exists to melt out such a build up.
Temperature ad&ustment by chemical heating.
<=awasaki Top 7lowing "under licence from =awasaki 6teel -orporation#
Principle
The principle of the recirculatory degassing process has already been described.
This is a development of the recirculatory degassing process in which the vacuum vessel is
equipped with a vertical oxygen blowing lance which is located in the connection between the
vacuum vessel and the vacuum pumping system.
The lance, which is water cooled, can be raised and lowered as required, depending on the type
of operation to which the lance is being applied. 4hen the lance is in a set treatment position, an
inflatable seal makes a vacuum tight connection between the seal housing and the lance itself.
9uring vacuum treatment oxygen can be blown through the lance at a controlled rate onto the
surface of the steel inside the vacuum vessel.
There are two main reasons for oxygen blowing during treatment whilst under vacuum. These are
as follows:
9ecarburisation
;nder vacuum carbon and oxygen react together to form carbon monoxide, which is removed by
the vacuum pumps. /f the carbon content of the liquid steel is too high before vacuum treatment,
then the final carbon level will also be too high, since the oxygen content will be too low to allow
complete decarburisation. 7y blowing oxygen onto the surface of the steel under vacuum
however, this situation is rectified. This enables the operator to make low carbon steels even from
steels tapped at high initial carbon levels. /n some cases higher tap carbon contents may be
adopted deliberately, to reduce the tap temperature, oxidation state and therefore the load on the
convertor refractories. 8ower tap temperatures can also produce lower nitrogen and phosphorus
contents, both elements being generally speaking deleterious to the mechanical properties of the
steel.
)eheating
The installation of an oxygen lance into the recirculatory degassing unit gives the operator a steel
reheating facility.
The principle of the reheating process is the exothermic reaction between aluminium dissolved in
the liquid steel and oxygen blown onto the surface of the liquid steel. The oxygen and aluminium
react to form alumina "Al(!5# and generate heat in the liquid steel. The oxidation of approximately
$ kilogramme of aluminium per tonne of liquid steel is sufficient to raise the temperature of the
liquid steel by about 53>-. /n practice, the control system calculates the amount of aluminium and
oxygen required to achieve a given amount of reheat.
Aluminium is then added to the steel in the vacuum vessel at a controlled rate whilst at the same
time oxygen is blown onto the steel surface, also at a controlled rate, which matches the rate of
aluminium addition.
The resultant exothermic reaction generates enough heat to reheat the liquid steel at a
predetermined rate of between ,>- and $3>- per minute, depending mainly on ladle sie.
?ultifunction 8ance
A further development of the oxygen lance is the multi function lance, which combines the
function of the oxygen lance, used for decarburisation and reheating during treatment with vessel
heating, using an oxygen - gas burner between treatments.
The multi function lance is designed to combine both functions in a single unit, and is located
vertically in the connection between the vacuum vessel and the vacuum pumping system.
Process
The basic process and the metallurgical capabilities have already been described under the
recirculatory degassing process description.
The addition of an oxygen lance or multi function lance unit extends the range of metallurgical
treatments in two ways. /n the case of deep decarburisation, oxygen is blown onto the surface of
the liquid steel in the vacuum vessel during treatment. This increases the amount of carbon
removed, and also increases the rate at which the carbon is removed. 7oth factors are important
when treating steel with higher initial tap carbon contents.
/n the case of reheating the operator measures the temperature of the liquid steel after
deoxidation and then determines the amount of reheat required. The control system calculates
the amount of aluminium and oxygen necessary to achieve the reheat, and then controls and
monitors both aluminium addition and oxygen blowing rates.
Application
The recirculatory degassing process with oxygen lance or multifunction lance is a more versatile
version of the recirculatory degassing process. /t can be applied to all the grades of steel
previously mentioned in connection with the recirculatory degassing process,
/n addition it is much less sensitive to tap temperature, and, in the case of low carbon steel
production, tap carbon contents.
As with the recirculatory degassing process, the ladle sie varies between %, and %33 tonnes,
with most units being in the range $33 tonnes or more.
Advantages
The recirculatory degassing process is very adaptable, being suitable for hydrogen removal,
general analytical control, and particularly suitable for the vacuum treatment of unkilled steels.
The addition of the oxygen lance or multi function lance makes the process even more versatile,
since it adds a reheat facility, and reduces the limitation on tap temperatures and tap carbon
levels.
9eslagging of the ladle before treatment is not required.
.o porous plugs are required.
Temperature loses are low, and there is no requirement for change to the normal tapping weight
or additional freeboards "i.e. reduced tap weights#.
Ladle Degasser
9uring treatment the ladle is sealed with a vacuum tight cover or, alternatively, placed into a
vacuum tight tank sealed with a moveable cover. 1ffective homogenisation is guaranteed with
modern inert gas stirring systems. The extensive exposure of liquid steel to the vacuum serves
not only to lower the carbon, hydrogen, oxygen and nitrogen contents considerably, but also
enhances any desulphurisation.
Advantages:
?uch reduced hydrogen levels after a short treatment time.
9esulphurisation to below (3 ppm 6.
+acuum decarburisation to less than (3 ppm -.
)emoval of nitrogen
1ffective flotation of non metallic inclusions.
Achievement of very narrow tolerance bands.
)elatively low investment cost.
0igh availability with relatively low maintenance costs.
:ossible modifications can include:
o +!9 refining for stainless steels.
o -hemical heating.
o 4ire feeding
Principle
The principle of the ladle degassing process is as follows:-
A ladle of liquid steel is transferred by overhead crane from the melting unit to the ladle degasser.
The ladle is then placed in a cylindrical tank which can be located in a pit, or at floor level,
depending on headroom.
The tank is constructed from steel plate and is lined with a protective refractory facing.
4hen the ladle has been located in the tank, an inert gas supply is connected to one or more
porous plugs located in the refractory lining in the bottom of the ladle. /nert gas, is blown through
the plug or plugs at a controlled rate to stir the liquid steel in the ladle, and expose the surface of
the liquid steel by pushing aside the slag layer on the surface of the liquid steel.
The tank, which is equipped with a flange around the upper periphery of the tank sidewall, is then
sealed by a cover which is normally located in a self propelled car. The car drives over the tank,
and the cover is lowered until the flange round the lower edge of the cover is in contact with the
tank flange.
An @!@ ring seal between the two flanges creates a vacuum tight seal.
The volume enclosed by the tank and cover is then evacuated by a set of powerful vacuum
pumps connected to the tank. As the pressure in the tank falls, the flow of inert gas to the porous
plug or plugs in the bottom of the ladle can be ad&usted to create the required degree of
turbulence in the ladle. 9issolved gases such as hydrogen are removed by diffusion from the
surface of the steel to the low pressure surrounding atmosphere.
/n the case of unkilled steels, carbon and oxygen, both dissolved in the steel, will react under
vacuum to form carbon monoxide, which is then removed from the steel in bubble form and
extracted from the tank by the vacuum system. ;nder vacuum conditions the steel can boil quite
violently, and for this reason there should be sufficient freeboard in the ladle above the normal
liquid steel surface to accommodate the reaction.
.ormally a freeboard of at least $.3m is recommended for ladle degassing.
The vacuum cover is equipped with a vacuum lock which permits the automatic weighing and
batching of alloy additions externally, and their addition to the liquid steel in the ladle without
disturbing the low pressure conditions within the vacuum tank during treatment.
There are variations of the tank degasser process where, for example, the tank is located on a
self propelled car. After the ladle has been placed in the tank, the tank and car are driven under
the vacuum cover which is then lowered onto the tank.
/n another variation the ladle itself is vacuum tight, and is sealed directly by the cover which is
lowered onto a flange welded round the periphery of the ladle, below the top of the ladle.
The principle of ladle degassing is however the same in each case.
Process
The ladle is placed in the tank, and the argon flow to the porous plug or plugs is ad&usted to give
the required degree of stirring.
The cover is driven into position and lowered until flange to flange contact is made, and the ! ring
between the two flanges provides a vacuum tight seal.
The tank is then evacuated by the vacuum pumps. As the pressure falls the action of the liquid
steel in the ladle is closely observed via sight port or closed circuit camera. The required degree
of turbulence and exposure is controlled by the argon flow rate and level of vacuum.
*or low hydrogen steels the required pressure level is very low, and the steel is held at low
pressure for a minimum time period.
To produce low sulphur steels, synthetic slags are added to the ladle surface. This can be done
prior to or during treatment. The vigorous stirring action during ladle degassing ensures a high
degree of slag - metal contact, which is required to produce low sulphur steels.
8adle degassing is also capable of producing low nitrogen steels, since during the process the
addition of the correct type of synthetic top slag and the vigorous slag - metal stirring motion
produces, as mentioned earlier, very low sulphur contents. At very low sulphur levels "less then
(3ppm# nitrogen is removed from the steel during ladle degassing.
The nitrogen removal mechanism is mainly due to the flushing action of the argon bubbles as
they rise to the surface of the liquid steel.
6ampler units can be provided to take chemical samples and temperatures under vacuum.
Tank degassers can also be equipped with wire feed machines for fine alloy trimming and
inclusion modification.
At the end of the process the tank is flooded back to atmospheric pressure, usually with air. The
cover is raised and retracted, and the ladle removed from the tank by the over head crane.
As the ladle is removed the argon connections to the porous plugs are disconnected either
manually or automatically.
Application
The ladle degassing process can be applied to a whole range of plate steels, alloy steels and
structural steels. /t is of particular interest where the combination of low hydrogen, low sulphur
and low nitrogen are required, as is the case in 0/- "hydrogen induced cracking# grades for
pipeline steels for example.
6ulphur removal by synthetic top slag is particularly effective in ladle degassing.
*or unkilled and low carbon steels ladle degassing is less effective due to the difficulty in
containing the reaction and the high amount of freeboard required.
0ydrogen removal is quite good, and cleanness levels can be exceptionally good if slag
chemistry is correct.
8adle sies for the ladle degassing process are normally in the range 53 to (,3 tonnes. 6mall
ladle sies are more difficult to treat due to the rate of temperature loss.
Advantages
8adle degassing is probably the most versatile degassing process, being capable of hydrogen
removal, sulphur removal, nitrogen removal and decarburisation.
The unit can be switched on and off, as required.
-ompared to the recirculatory process, ladle degassing is relatively simple, and cheaper both to
install and operate.
)ac**+ O,-gen Decar.*risation
The blowing of oxygen under vacuum conditions together with the use of low cost ferroalloys
offers a time and cost saving method of producing stainless, corrosion and heat resisting steel
grades.
4ithout the application of secondary metallurgical technology it would be difficult to equal the cost
effectiveness of this process.
Advantages:
+acuum decarburisation from virtually any practical initial carbon level.
-ontrolled achievement of very low carbon, nitrogen, hydrogen and sulphur levels.
6pecial grades, e.g. superferrite, can be produced.
6mall chromium losses.
.arrow composition tolerances.
The plant can be used as a conventional tank degasser and for the chemical heating of
liquid steel.
Principle
The vacuum oxygen decarburisation process was developed specifically for the production of
stainless steel, and the principle is as follows:-
The ladle of liquid stainless steel is placed in a vacuum tank by the overhead crane. The vacuum
tank is constructed from steel plate with a protective inner refractory lining. 4hen the ladle has
been located in the vacuum tank a supply of inert gas, normally argon, is connected to one or
more porous plugs located in the refractory lining in the bottom of the ladle. The inert gas
connections can be made either manually or automatically. The flow of inert gas to the porous
plug is then ad&usted until the required degree of stirring action is achieved within the ladle
contents.
A cover is then placed on the tank to complete the enclosure of the ladle. The cover is a steel
plate construction, and is normally located in a self propelled car, which can be driven from a
parked position to a position directly above the vacuum tank. The cover is then lowered until the
flange which runs round the periphery of the tank upper side wall is in contact with the flange
welded to the lower edge of the cover. A vacuum tight &oint is made between the two flanges by
an @!@ ring.
The vacuum tank is then evacuated by a set of powerful vacuum pumps connected to the tank.
As the pressure falls the reaction of the liquid steel in the ladle is observed, and the pressure and
inert gas flow rate ad&usted if required to maintain the required degree of turbulence.
At predetermined pressure oxygen lance which is located in the vacuum cover is lowered until the
tip of the lance is a set distance above the liquid steel. !xygen is then blown onto the surface of
the liquid stainless steel at a controlled rate, whilst the liquid stainless steel is stirred by inert gas.
7ecause the reaction takes place under vacuum, the thermodynamics of the process favour the
formation of a gaseous product which is continuously removed from the vacuum tank by the
vacuum pumping system. /n this case the oxygen blown onto the surface of the liquid stainless
steel reacts with dissolved carbon to form carbon monoxide, rather than with chromium in the
steel to form chromium oxide. 7y oxygen blowing under vacuum, much lower levels of carbon can
be achieved with significantly lower chromium oxidation than would be possible at atmospheric
pressure.
The vacuum oxygen decarburisation process therefore allows the use of high carbon
ferrochromium in the furnace charge as opposed to the more expensive low carbon
ferrochromium.
Process
8iquid stainless steel with carbon content normally between 3.,3A and $.33A is tapped from the
furnace and transferred to the vacuum oxygen decarburisation unit. ;sually lime is added at tap
to neutralise any silica formed during the process.
0aving ad&usted the inert gas stirring rate and evacuated the tank, the liquid stainless steel in the
ladle is refined by oxygen blowing. 9uring the oxygen blow, the pressure in the vacuum tank is
normally between ,3 - $,3mbar. The amount of oxygen to be blown is precalculated based on
the initial and final required carbon levels. The blow rate is controlled, and based on ladle sie
and vacuum pumping capacity. 1xhaust gas analysis equipment is used to monitor the progress
of the reaction and determine the end point.
After finishing the oxygen blow as determined by the end point, the pressure level in the vacuum
tank is reduced to its lowest level, about $ mbar, in order to achieve the lowest final carbon level.
0aving completed the vacuum decarburisation phase, the stainless steel is deoxidised, and the
chromium oxide in the slag reduced by the addition of aluminium and'or ferro silicon.
The stainless steel is then sampled, and final analysis ad&ustments made. These can be made if
required, under vacuum via the vacuum lock located on the cover. The vacuum lock allows the
addition of weighed batches of ferroalloy without disturbing the low pressure conditions inside the
vacuum tank.
At the end of the process the vacuum tank is flooded back to atmospheric pressure, and the
cover is retracted. The ladle is removed from the tank by the overhead crane. As the ladle is
removed the inert gas connection to the ladle is disconnected either manually or automatically.
Application
The vacuum oxygen decarburisation process is a specialist process developed for the production
of stainless steel, and in particular low carbon stainless steel. The process can however also be
used as a ladle degasser, with or without the use of the oxygen lance.
Advantages
The vacuum oxygen decarburisation process is an economic way of producing low carbon
stainless steel.
7ecause of the vacuum, low residual levels of volatile @tramp@ elements such as tin and lead can
be achieved.
The process is a single ladle process with all reactions being carried out in the same ladle.
/n addition to the above, the process has all the potential of the ladle process described earlier,
for a much wider range of steels than &ust stainless steel.
Ladle /*rnace
4ith a ladle furnace liquid steel can be heated, alloyed and desulphurised under an inert gas
atmosphere. The essential homogenisation is achieved with inert gas stirring.
Another purpose of the ladle furnace is to act as a holding furnace between primary melting unit
and the continuous casting machine.
Advantages:
/ncreasing the productivity of the primary melting unit.
8owering of the tap temperature.
)eduction in the necessity to reblow in converter.
Avoiding re-cycling of ladles.
Achieving narrow composition tolerances.
8ow total oxygen content.
1fficient desulphurisation.
:recise temperature ad&ustment.
:ossible modifications include:
o 4ire feeding.
o :owder in&ection.
Principle
The principle of the ladle furnace is as follows:-
A ladle of liquid steel is transferred by car or turntable to a position below the ladle cover.
Alternatively, the ladle may be placed on a stand by the overhead crane, and the ladle cover
slewed into position above the ladle.
The cover, which can be refractory lined or water cooled or a combination of both, is then lowered
until the lower edge of the cover is on or below the lip of the ladle.
9uring the process the liquid steel in the ladle is continuously stirred by inert gas which is
introduced via one or more porous plugs located in the refractory lining of the bottom of the ladle.
There are three graphite electrodes located in the ladle cover, passing through ports in the cover.
The electrodes are gripped by water cooled copper clamps, and connected to an arc furnace type
transformer by current carrying electrode arms and flexible bus tubes.
1ach electrode arm is attached to a vertical mast which incorporates a hydraulic ram. 1ach
electrode arm and mast assembly can be raised and lowered independently by a common
hydraulic power pack via a servo valve system.
4ith the ladle cover lowered, the transformer is energised and the electrodes lowered until each
electrode strikes an arc onto the surface of the liquid steel in the ladle.
The arc length is determined by the tap voltage, and the operator is able to select from a range of
tap voltages and arc currents depending on the rate of heating required.
A layer of slag on top of the ladle is required to submerge the arc and protect the refractory lining
of the ladle sidewall.
0eat generated by the arcs is distributed and homogenised by the inert gas stirring and mixing of
the ladle contents.
The ladle cover is designed to remove fumes generated during electric arc reheating and also, as
far as possible, prevent atmospheric contamination.
Ancillary equipment such as alloy addition hoppers, samplers, wire feed machines and powder
in&ection facilities can all be added to the basic ladle furnace to increase the metallurgical
versatility of the process.
Process
6ynthetic slag is added to the ladle prior to or during treatment to provide the correct conditions
for a stable arc and to protect the ladle sidewall.
The required tap voltage is selected by the operator or computer, depending on the rate of
heating required. The electrodes drive down until each strikes an arc.
The electrode regulator then controls the electrode mast and hence electrode position to maintain
the required arc voltage and arc length. 9uring reheating the liquid steel is continuously stirred by
inert gas to prevent any temperature stratification.
At the end of the reheating period the arcs are broken by raising the electrodes to their top
positions.
Alloy additions can be made as required either during or after reheating, via the alloy hopper and
chute which passes through the ladle cover. 6ampling, powder in&ection and wire feeding, if these
facilities are provided, are done between reheating phases with the electrodes de-energised.
4hen the liquid steel has been alloyed to the required chemical analysis, a final reheat phase
takes place to bring the liquid steel to the correct temperature.
The electrodes are raised and de-energised and the ladle cover is raised. The ladle is then
removed by car and'or overhead crane.
Application
The ladle furnace process is used on a wide range of steels, including probably all but the lowest
carbon grades.
/t is a non chemical form of heating and is applied as a @one stop@ form of ladle steelmaking for
grades where hydrogen content is not critical. The ability to reheat can be used to reduce tap
temperatures, which has a beneficial effect on the furnace or convertor lining, and is useful as a
way of coordinating the operation of the furnace or convertor and continuous casting machine,
which have different cycle times, by acting as a holding unit.
8adle sies can vary from (3 tonnes up to %33 tonnes. :robably the widest range of ladle sies.
The lower limit is determined by the minimum electrode pitch circle diameter.
Advantages
The ladle furnace is a non chemical heating method which raises the temperatures of the steel
without significant effect on the composition of the steel. /t can be used for all grades of steel
including those which are unkilled or semi killed.
8adle furnaces have the option of operating with either inert gas stirring, using porous plugs, or
induction stirring where no plug is required.
*reeboard requirements are minimal.
CAS Units'
/n this process the alloying additions are made to the slag free steel surface under exclusion of air
within a partially immersed refractory clad bell.
Advantages
.o contact with oxygen from the atmosphere, minimised slag contact.
0igh alloy recovery due to the additions being made directly to the slag free surface of
the liquid steel.
8ow temperature losses.
Achievement of narrow composition tolerances.
Ad&ustment of the required casting temperature.
1xceptionally high degree of cleanness by separation of non-metallic inclusions.
6hort treatment periods.
8ow investment and running costs.
:ossible plant modifications include:
o -hemical heating.
o 4ire feeding
o *acilities to add synthetic slag to achieve a high degree of desulphurisation.
< -A6 B -omposition Ad&ustment 6ealing by Argon 7ubbling ";nder licence from .ippon 6teel
-orporation#
CAS%O# Unit'
The above is an extension of the -A6 process and offers the possibility to heat ladles by the
exothermic reaction between oxygen and aluminium.
Advantages
The same features as the -A6 process.
0eating rates of up to $,>-'min.
6hort treatment times.
8ow investment and running costs.
Avoidance of re-cycling of ladles when delays at the continuous casting machine call for
temperature ad&ustment.
< -A6-!7 B -omposition Ad&ustment 6ealing by Argon 7ubbling with !xygen 7lowing ";nder
licence from .ippon 6teel -orporation#
Principle
The principle of the chemical heating process is as follows:-
A ladle of liquid steel is transferred by car or turntable into a position below the snorkel of the unit.
The snorkel is a refractory faced bell shaped receiver which is clamped to a moving arm. The arm
is raised and lowered as required by a winch system. A vertical mast guides the moving carriage
which is connected to the moving arm.
4hen the ladle is in position, an inert gas supply is connected to a porous plug located in the
refractory lining of the bottom of the ladle. The inert gas flow is ad&usted until a slag free area is
created on the top of the ladle.
The snorkel is then lowered until it is partially immersed in the liquid steel, enclosing the slag free
area created by the inert gas. 6ince the inert gas then bubbles out of the steel and into the
snorkel, displacing the air in the snorkel, this gradually creates an inert atmosphere inside the
snorkel.
*erroalloys can be added from a remote alloy system which weighs batches and delivers the
additions, and adds them to the liquid steel surface within the snorkel via a telescopic chute
arrangement connected to a tube which sits on top of the neck of the snorkel. The inert gas
stirring action rapidly dissolves the ferroalloys, and the absence of slag within the snorkel and
inert atmosphere created by the inert gas stirring, ensure high rates of alloy recovery and good
control of chemical composition.
)eheating is achieved by adding aluminium to the liquid steel within the snorkel and, at the same
time, blowing oxygen onto the surface of the steel. The oxygen reacts with the aluminium
dissolved in the steel to produce alumina, Al(!5, which is an exothermic reaction.
The oxidation of $ =g of aluminium per tonne of steel is sufficient to increase the temperature of
the steel by about 53>-.
The rate of aluminium addition is designed to reheat the steel at a predetermined rate. The
oxygen blow rate is then controlled to match the aluminium addition rate, in stochiometric ratio.
)eheat rates of up to $,>-'min can be achieved by chemical heating, depending on ladle sie.
*or large ladles reheat rates of $3>-'min are more practical.
Process
The ladle of liquid steel, which is equipped with a porous plug, is positioned below the snorkel.
The argon which flows through the porous plug is ad&usted until a slag free area of approximately
$.,m in diameter is created on the surface of the ladle. The snorkel is then lowered until it is
immersed to a predetermined distance below the surface of the liquid steel in the ladle. This can
be done automatically, if the freeboard in the ladle is measured before immersion.
The operator selects the amount of reheat required, and the rate of reheat.
These parameters are then used by the control system to calculate the amount of aluminium and
oxygen required to achieve the amount of reheat, and the rate of aluminium addition and oxygen
blow rate to achieve the rate of heating.
Aluminium for reheating is delivered from a bunker on load cells which monitors and controls the
rate of feed. !xygen is also controlled by a flow control valve to match the aluminium feed rate, in
stochiometric ratio.
As the aluminium is beginning to be added to the steel surface within the snorkel, the oxygen
lance is lowered to a preset distance above the steel surface in the snorkel, and oxygen is blown
at a controlled rate onto the steel surface.
4hen the reheat period is complete a temperature measurement is taken after several minutes of
inert gas stirring to homogenise the ladle contents.
)eheat normally takes place after alloying. /nert gas stirring may continue for sometime after
reheating to ensure that the alumina particles formed during reheating are removed by floatation.
At the end of the treatment, the snorkel is raised from the ladle, and the ladle is removed by car
or turntable. 7efore removal the connection of the inert gas to the porous plug in the ladle is
disconnected either automatically or manually.
Application
The chemical reheating process can be applied to any grade of steel which is aluminium killed.
6ince it is normally not only a reheat process but also an alloying process under inert atmosphere
it is particularly suitable for sheet and other aluminium killed grades where low hydrogen is not a
requirement.
Advantages
The chemical reheat process is relatively cheap, being probably half to one third the price of the
ladle furnace.
.o strengthening of the shop electrical system is required.
.o special ladles required.
)educed slag line wear as compared with ladle furnace practice.
.o synthetic slag requirement.
.o free board limitations.
-hemical heating produces a much more rapid heating rate "probably twice as fast as the ladle
furnace# and therefore potentially shorter treatment times.
The atmospheric pick up is relatively small.
ot 0etal Des*lp1*risation
The treatment of liquid iron is carried out by lance in&ection with -a-(, ?g, ?g'-a-( or a mixture
of -a!'-a*(. This is carried out in con&unction with a deslagging process.
Advantages:
8ow cost reagents.
6ulphur levels down to $3 ppm 6.
)easonable investment cost.
1fficient deslagging in shortest possible time.
8ow iron losses.
Principle
The principle of the hot metal desulphurisation process is as follows:-
Treatment can take place in the torpedo ladle or the transfer ladle. 7ecause of the shape of the
transfer ladle, which is much easier to deslag, and has a high metal bath depth, this is the
preferred method.
6ulphur is removed from the hot metal by in&ecting a range of fine powders into the liquid hot
metal through an immersed lance.
The most commonly used powders are lime, calcium carbide and magnesium. ;sually these
powders are used in combination, lime plus magnesium or calcium carbide plus magnesium for
example.
The powders are pneumatically transported from pressurised containers equipped with
fluidisation discharge cones down a fixed and flexible pipeline to the head of an in&ection lance.
The refractory coated lance is attached to a carriage which can be raised and lowered as
required. 0aving established the powder flow, the lance is driven down into the ladle until the tip
of the lance is close to the bottom of the ladle. As the powder leaves the tip of the lance, and
rises up through the hot metal, it reacts with the sulphur dissolved in the hot metal to form
sulphides, which are trapped in the slag on top of the ladle.
After the in&ection process the sulphur rich slag on top of the ladle is removed by tilting the ladle
and skimming the slag off the surface of the ladle, using a slag skimming machine, into a slag pot
or pen. The ladle can then be transferred to the next step of the steelmaking process.
Process
Cenerally speaking hot metal desulphurisation takes place in the transfer ladle.
0ot metal from the torpedo or mixer is tapped into the transfer ladle which is then transferred by
overhead crane to the treatment station. This consists of a ladle stand in an enclosure. !nce the
ladle is positioned on the stand, the enclosure is sealed by a hood. The enclosure or hood is
connected to a fume extraction and cleaning system.
A temperature and chemical sample is taken, and from the initial and final required sulphur levels
the amounts of desulphurisation reagents are automatically calculated.
The in&ection lance is lowered to a preset position above the hot metal surface, and the transport
gas which is dry nitrogen is blown through the powder transport line and lance at a controlled
rate. 0aving established the transport gas flow, the shut off valve on the bottom of the lime or
calcium carbide dispenser opens, and lime or calcium carbide is blown down the lance. The
powder flow rate is controlled by a material flow control valve on the bottom of the dispenser, and
the powder flow rate monitored by load cells below the dispenser.
4hen the measured powder flow rate reaches a minimum preset value, the lance is driven down
into the hot metal to a predetermined position where the tip is close to the bottom of the ladle.
?agnesium can be introduced into the powder flow when the lance is fully immersed. The flow
rate of magnesium is controlled by a similar material flow control valve as the lime or calcium
carbide, and the powder flow rate is monitored by load cells below the dispenser.
The in&ection of two powders simultaneously into a common line is called co-in&ection. "A single
powder in&ection such as calcium carbide only is called mono-in&ection#.
/n&ection continues until all the magnesium has been in&ected, and the lance is then retracted
automatically as the lime or calcium carbide approaches its required amount. To prevent lance
blockage, powder flow is maintained until the lance tip is clear of the hot metal.
The powder flow is then turned off, followed by the transport gas flow, and the lance fully
retracted.
*ollowing in&ection, the ladle is deslagged by tilting the frame or stand in which the ladle is
seated, or rotating the ladle about its trunnions in the stand.
6lag is drawn over the tip of the ladle using a paddle attached to the arm of a slag skimming
machine.
The arm of the machine is capable of horiontal, pivoting and slewing motions. 6lag skimmed
from the ladle surface falls into a slag pot or into a slag pen, from where it is subsequently
removed.
After deslagging the ladle is rotated back to its vertical position. The ladle is sampled, and the
enclosure hood removed. The ladle is then transferred to the next stage of the steelmaking
process.
Application
0ot metal desulphurisation can be applied to all grades of steel which are to be subsequently
processed in a convertor or electric arc furnace. 7y doing so, the metallurgical load on the
primary melting unit is significantly reduced, enabling low sulphur steels to be produced with
reduced tap to tap times.
8adle sies vary between ,3 tonnes and 5,3 tonnes.
Advantages
0ot metal desulphurisation reduces the low sulphur requirement of the blast furnace, which
means that there is a possibility of cheaper blast furnace charge costs. /t also reduces the
metallurgical demand on the primary melting unit, either convertor or electric arc furnace,
reducing slag making material requirements and tap to tap time.
Steel Des*lp1*risation Unit
The treatment of liquid steel is carried out by lance in&ection of calcium bearing compounds or
with vigorous argon stirring of synthetic slag.
Advantages:
)elatively low investment cost.
6ulphur levels to D(3 ppm 6.
Cood recovery of reagents under argon shrouding.
?odification of non-metallic inclusions.
1ffective separation of non-metallic inclusions.
4ire feeding facilities can be added.
Principle
The principle of the desulphurisation process is as follows:-
A ladle of liquid steel is transferred by car or turntable to the desulphurisation station. /n this
position, the ladle is covered by a hood which is designed to capture and extract the fume
generated during the process, and, at the same time, minimise contact between the surface of
the steel and the atmosphere.
*or effective desulphurisation, the amount of slag carry-over from the furnace or convertor is
minimised, and a basic synthetic slag is added to the ladle surface.
9esulphurisation is achieved by the deep in&ection of a mixture of elements including lime-
fluorspar and calcium bearing compounds such as calcium silicide or calcium itself. These
materials are in&ected through an immersed lance as fine powder, using argon as a carrier gas.
6ulphur dissolved in the liquid steel combines with calcium in the in&ected materials to form
calcium sulphide, which floats up into the top slag.
The combination of the reaction between sulphur in the liquid steel and both the in&ected
materials and the top slag is effective in producing extremely low residual sulphur levels of less
than $3 ppm.
To achieve good results, the steel must be fully killed, with very low residual oxygen levels. The
top slag must be within a fairly narrow compositional range, with very low levels of reducible
oxides such as *e!, ?n! and :(!,.
Process
The furnace or convertor slag is held back during tapping, as far as possible, or removed by
deslagging after tap. The residual tapping slag is treated with aluminium pellets to reduce any
remaining reducible oxides.
6ynthetic slag is added to bring the top slag composition within the required range for effective
desulphurisation.
The ladle is located in the treatment station, and then sealed as far as possible by a ladle cover.
The ladle cover serves two functions, the first being to capture and remove fume generated
during the process. The fume is removed by a duct which connects the ladle cover to a fabric
filter duct cleaning unit. The second function of the ladle cover is to minimise atmospheric contact
with the surface of the steel, which would cause oxidation and nitrogen pick up. *or this reason,
the ladle cover design is relatively sophisticated.
*luxing of the ladle top slag is done by argon stirring, either by top lance or bottom porous plug.
4hen the top slag is in the required condition, desulphurisation by in&ection begins.
A lime-fluospar mixture, which may be prefused, is in&ected into the steel through an immersed
lance. Argon is used as a carrier gas. To increase the effectiveness, the lance tip is close to the
bottom of the ladle. -alcium compounds are also in&ected, either in combination with lime-spar
"co-in&ection# or separately "mono or sequential in&ection#.
The amount of reagent in&ected is obviously dependant on the initial sulphur level and final
required level. -alcium is also used to modify the shape of the remaining sulphides.
7oth the total amount and the rate of in&ection are predetermined and controlled.
At the end of the in&ection, the lance is automatically retracted, and a sample is taken. The ladle
cover is then raised and the ladle removed.
Application
The desulphurisation process is obviously applied to all steel grades where low sulphur content
and'or controlled sulphide shape are important. This is particularly true of heavy plate grades and
certain pipeline steels.
Any grade of steel where uniform mechanical properties in all directions is important would
benefit from this process.
8adle sies range from (3 tonnes up to %33 tonnes.
Advantages
9esulphurisation by in&ection is a very effective way of producing ultra low sulphur steels, and of
modifying the shape of the remaining sulphides.
*reeboard requirements are not particularly critical, and standard ladles can be used.
Temperature losses are not excessive.
Ladle Treat+ent Station
+acmetal ";.=.# 8imited have built a number of 8adle Treatment 6tations which allow the
treatment of steel in order to bring it into the required chemical composition prior to transfer for
casting.
The 8adle Treatment 6tation can be installed with a full ferro alloy system, wire feed machines
and inert gas stirring as required depending upon the treatment.
Principle
The principle of the ladle treatment station is as follows:
The ladle treatment station is designed to treat steel from the furnace or convertor in order to
bring it into the required chemical composition and temperature prior to transfer for casting. The
design of the ladle treatment station depends on the range of metallurgical capability required.
The principle however is as follows.
A ladle of liquid steel is transferred by car or overhead crane to the ladle treatment station. The
liquid steel in the ladle is stirred by one or more porous plugs, located in the refractory bottom of
the ladle, which are connected to a supply of inert gas either manually or automatically when the
ladle is in its treatment position. After homogenisation a sample is taken. 7ased on the analysis of
the sample, ferro alloys are added to the ladle to achieve the required chemical composition. /nert
gas stirring helps to create a slag free area on top of the ladle to which additions can be made,
and the stirring action of the inert gas helps to rapidly dissolve the additions.
9uring treatment the ladle is sealed by a cover which helps to prevent atmospheric
contamination, and is connected to an extraction duct to remove any fume generated during
treatment.
A wire feed machine may be installed for fine alloy trimming or for modification of sulphide
inclusions.
Process
The ladle is tapped as slag free as possible and transferred to the ladle treatment station. An inert
gas stirring supply is connected, and the ladle contents stirred to homogenise the chemical
composition and remove temperature stratification. A sample is then taken, and, based on the
analysis of the sample, ad&ustments are made to the chemical composition of the liquid steel.
This can be done by adding weighed amounts of ferro alloys via an alloy hopper and chute, or by
in&ecting wire from a wire feeder machine. A combination of alloy system and wire feeder give a
more flexible facility. 4ire feeding can be used for ad&ustment of the aluminium content, or, using
cored wire, for inclusion modification or alloy trimming.
Application
The ladle treatment process can be applied to almost all non critical grades of steel as a simple
method of ad&usting chemical composition and removing temperature stratification.
8adle sies can range from the smallest "$3 tonnes# up to %33 tonnes. /n the case of the largest
ladles, more than one top lance or porous plug would be required for rapid homogenisation.
8adle stirring can be by either top lance or bottom porous plug for increased flexibility.
Advantages
The ladle treatment process is simple and versatile. -apital costs are low, and operational costs
very low, since the unit can be switched on and off as required.
7y using top lance or bottom porous plug, the process is made very flexible, and steel can still be
treated if the porous plug is blocked.
*reeboard is not a problem.