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A special issue of Metals (ISSN 2075-4701).

Deadline for manuscript submissions: closed (31 July 2022) | Viewed by 26252

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Dr. Guangsheng Wei

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Guest Editor

School of Metallurgical and Ecological Engineering, University of Science and Technology Beijing, Beijing 100083, China
Interests: EAF steelmaking; CO₂ utilization; injection metallurgy; low-carbon metallurgy
Special Issues, Collections and Topics in MDPI journals

Dr. Lingzhi Yang

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Guest Editor

School of Minerals Processing and Bioengineering, Central South University, Changsha 410083, China
Interests: simulation; theoretical model; steelmaking; comprehensive utilization of complex ores
Special Issues, Collections and Topics in MDPI journals

Dr. Ming Lv

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Guest Editor

College of Metallurgical Engineering, Xi'an University of Architecture and Technology, Xi’an 710055, China
Interests: steelmaking; non-metallic inclusions; clean steel; secondary refining; slag system
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

The iron and steel industry is a major emitter of CO₂, especially in ironmaking and steelmaking processes. In the context of global low-carbon development, there is an urgent need for innovation in energy-saving and carbon reduction technology in the iron and steel industry. On one hand, iron and steel enterprises realize the transformation of energy structure by improving production processes, updating production equipment and using low-carbon energy. On the other hand, iron and steel enterprises and research institutes have committed to the development of deep decarbonization and zero carbon technologies. In recent years, clean ironmaking and steelmaking processes have been developing rapidly, especially in energy conservation, high efficiency, carbon emission reduction, energy structure adjustment, hydrogen metallurgy, electric arc furnace steelmaking, novel ironmaking and steelmaking technologies, and so on.

In this special issue, potential topics include, but are not limited to:

novel ironmaking and steelmaking technologies with low carbon emissions;
hydrogen metallurgy;
electric arc furnace steelmaking;
Renewable energy utilization in ironmaking and steelmaking processes;
Carbon capture, utilization and storage (CCUS) in in ironmaking and steelmaking processes;
Resource utilization of dust and slag.

Dr. Guangsheng Wei
Dr. Lingzhi Yang
Dr. Ming Lv
Guest Editors

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Keywords

novel ironmaking and steelmaking technologies with low carbon emissions
hydrogen metallurgy
electric arc furnace steelmaking
renewable energy utilization in ironmaking and steelmaking processes
carbon capture, utilization and storage (CCUS) in ironmaking and steelmaking processes
resource utilization of dust and slag

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Published Papers (12 papers)

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Research

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34 pages, 51667 KiB

Open AccessArticle

Comparison of Fluid Flow and Tracer Dispersion in Four-Strand Tundish under Fewer Strand Casting and Sudden Blockage of Strand Conditions

by Jintao Song, Yanzhao Luo, Yuqian Li, Zhijie Guo, Tianyang Wang, Mengjiao Geng, Wanming Lin, Jinping Fan and Chao Chen

Metals 2024, 14(5), 571; https://doi.org/10.3390/met14050571 - 12 May 2024

Cited by 1 | Viewed by 1180

Abstract

The study focuses on the four-strand tundish as the research object, aiming at the phenomenon of fewer strand casting (stable blockage) and sudden blockage of the tundish in industrial production. Numerical simulation methods are employed to compare the velocity vectors, flow fields, residence time distribution (RTD) curves, and outflow percentage curves under stable blockage and sudden blockage of the tundishes with a double-weir structure, U-shaped weir structure, and U-shaped weir structure with holes in the front. The results indicate that, after sudden blockage of the tundish strands, the flow field transitions from an unstable four-strand flow field to a stable three-strand flow field. Both the double-weir tundish and the U-shaped weir tundish reach a stable state after 200 s, while the U-shaped weir tundish with holes in the front reaches stability after 150 s. Additionally, compared to other structures, the tundish strands of the U-shaped weir with holes in the front are less affected by blockage, showing better consistency among strands and better adaptability under non-standard casting conditions. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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15 pages, 3807 KiB

Open AccessArticle

Supersonic Shrouding Methane Mixtures for Supersonic Combustion Coherent Jets

by Fei Zhao, Tianhao Di, Rong Zhu and Wenrui Wang

Metals 2023, 13(1), 123; https://doi.org/10.3390/met13010123 - 7 Jan 2023

Cited by 1 | Viewed by 1744

Abstract

A coherent jet oxygen supply plays a key role in the process of electric arc furnace steelmaking: it provides the necessary oxygen for the smelting of molten steel and promotes the flow of the molten pool. Compared with coherent jets in current use, the supersonic combustion coherent jet shrouded in supersonic methane gas could improve the impact capacity and stirring intensity of the molten pool. In order to reduce the smelting cost, the characteristics of the supersonic combustion coherent jet shrouding the supersonic methane and nitrogen mixtures must be studied. Computational fluid dynamics software is used to simulate the supersonic combustion coherent jet under various methane–nitrogen mixing conditions. The six-component combustion mechanism of methane and the Eddy Dissipation Concept combustion reaction model are selected. In agreement with thermal experiments, the simulation results show that the inclusion of a small amount of nitrogen has little effect on the combustion of supersonic shrouding methane gas. However, as the nitrogen content increases, the combustion region of supersonic shrouding gas becomes shorter in length, resulting in decreases in the lengths of the high-temperature, low-density region, and the high-turbulence-intensity region. These effects weaken the ability of the shrouding gas to envelop the main oxygen jet. The potential core length of the main oxygen jet decreases significantly; this decrease first accelerates and then decelerates. These results demonstrate the feasibility of including a small amount of nitrogen (about 10 wt%) in the supersonic shrouding methane gas without substantial negative impacts on the characteristics of the supersonic combustion coherent jet. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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8 pages, 4149 KiB

Open AccessArticle

Development of a Moving-Bed Ironmaking Process for Direct Gaseous Reduction of Iron Ore Concentrate

by Hong Yong Sohn and Syamantak Roy

Metals 2022, 12(11), 1889; https://doi.org/10.3390/met12111889 - 4 Nov 2022

Cited by 4 | Viewed by 1503

Abstract

A novel horizontal moving-bed ironmaking process has been developed at the University of Utah. This process uses iron concentrate directly without sintering or pelletization and reduces it with hydrogen in the temperature range of 500–1000 °C. The work started with the determination of the particle kinetics, which was then combined with diffusional effects to analyze the reduction rate of a particle bed. Based on the kinetics formulation, a mathematical model of the furnace for the proposed technology was developed for a modest industrial ironmaking operation designed to produce iron at a rate of 0.1 Mtpy. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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18 pages, 3245 KiB

Open AccessArticle

Prediction Model of End-Point Phosphorus Content in EAF Steelmaking Based on BP Neural Network with Periodical Data Optimization

by Yuchi Zou, Lingzhi Yang, Bo Li, Zefan Yan, Zhihui Li, Shuai Wang and Yufeng Guo

Metals 2022, 12(9), 1519; https://doi.org/10.3390/met12091519 - 14 Sep 2022

Cited by 8 | Viewed by 4163

Abstract

The phosphorus (P) content of molten steel is of great importance for the quality of steel products in the electric arc furnace (EAF) steelmaking process. At present, the initial conditions of smelting process in the prediction of end-point P content are still the core part. However, few studies focus on the influence between process data and end-point P content. In this research, the relationships between process data and end-point P content are explored by a BP neural network. Based on the theoretical analysis, influencing factors with high correlation were selected. The prediction model of P content coupled with process data and end-point P content is established. On this basis, the model is optimized with process data of oxygen supply and the time of the first addition of lime. Compared with the practical production data, the results indicate that the hit rate of the model optimized is 87.78% and 75.56% when prediction errors are within

\pm 0.004

and

\pm 0.003

of P content. The model established has achieved the effective prediction for end-point P content, and provided a reference for the control of P content in practical production. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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13 pages, 4801 KiB

Open AccessFeature PaperArticle

Optimization of the Liquid Steel Flow Behavior in the Tundish through Water Model Experiment, Numerical Simulation and Industrial Trial

by Junda Liu, Ping Zhou, Xiaotan Zuo, Di Wu and Dongling Wu

Metals 2022, 12(9), 1480; https://doi.org/10.3390/met12091480 - 6 Sep 2022

Cited by 9 | Viewed by 1845

Abstract

A reasonable tundish flow behavior could improve liquid steel cleanliness by promoting floating and removal of the inclusions. The flow behaviors of the tundish could be obtained by water model experiments and numerical simulations, respectively. However, the difference in density between the tracer and water in the experiment can contribute to notable errors. A new type of tracer, which is a mixture of potassium chloride (KCl) and ethanol, was proposed in this study to reduce the errors. The numerical simulation model was validated by the experimental data and its error was below 2%. By comparing the flow behaviors in seven tundishes with different inner structures obtained by simulation, it is found that the C1 can significantly reduce the dead volume ratio and C4 can improve the uniformity of liquid steel charged though each outlet. The structural strength of the baffle in C1 scheme was not considered, resulting in a crack of the baffle in the industrial trial. Industrial trials of the molten steel flow in the C4-based tundish were conducted and reported a reduction of 43.81% in the inclusions over the prototype. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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16 pages, 5019 KiB

Open AccessArticle

Research on the Jet Characteristics and Dephosphorization Efficiency of Converter Oxygen Lance Blowing CO₂-O₂ Mixed Gas

by Guoli Wei, Changli Zhou, Shaoyan Hu, Jun Tian, Rong Zhu, Deyong Wang and Qingde Zhu

Metals 2022, 12(9), 1457; https://doi.org/10.3390/met12091457 - 30 Aug 2022

Cited by 2 | Viewed by 1872

Abstract

Utilization of CO₂ in steelmaking process has attracted extensive attention in recent years, not only because of its social benefits, but also its better metallurgical performance. Mixing CO₂ with O₂ blown by converter oxygen lance is gradually being adopted by steelmaking plants, due to its potential of reducing consumption and improving steel quality. In the present research, effect of mixing CO₂ on the jet characteristics of a four-nozzle oxygen lance was studied in detail by numerical simulation, taking the combustion behavior between supersonic jets and ambient atmosphere into consideration innovatively. The simulated results showed that the combustion flame is mainly distributed in the region between multiple jets, and the high temperature flame has a noticeable influence on the low-velocity region of the jet. Due to the dilution effect of CO₂, mixing CO₂ into the oxygen jets will reduce the maximum temperature of the flame and slow down the combustion rate. With the increase of CO₂ mixing ratio, the high-temperature zone of combustion flame moves away from the lance tip significantly. At the same distance from the nozzle, although mixing CO₂ can hardly increase the velocity magnitude of the jet, but it can achieve higher dynamic pressure, indicating stronger impacting power. Then the industrial experiment of top blowing O₂-CO₂ was carried out in a 120-ton converter. During the blowing time of 120~300 s, the mixing ratio of CO₂ was 15 vol.% for better dephosphorization, and no CO₂ was mixed in the rest time of blowing. Due to the stronger stirring and better thermodynamics, the average [P] content in the final molten steel was decreased from 0.0155 wt.% to 0.0129 wt.%, achieving higher dephosphorization efficiency. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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13 pages, 4611 KiB

Open AccessArticle

The Isolated Austenite Forming during High-Temperature Cooling and Its Influence on Pitting Corrosion Resistance in S32750 Duplex Stainless Steel

by Xiaohan Wu, Zhigang Song, Jianguo He, Zhiyi Bao, Han Feng, Wenjie Zheng and Yuliang Zhu

Metals 2022, 12(8), 1316; https://doi.org/10.3390/met12081316 - 5 Aug 2022

Cited by 1 | Viewed by 1388

Abstract

The formation mode of isolated austenite (IA) formed during high-temperature cooling and its effect on pitting corrosion resistance of S32750 DSS were investigated. As the structure formed during the high-temperature cooling process after hot rolling in S32750 duplex stainless steel (DSS), the precipitation of isolated austenite (IA) can be considered as the combined production of temperature and cooling rates. IA generated at the ferrite (α) grain boundaries or internal α and performed the K-S crystallographic relation with the α N element enriched in IA. The redistribution of elements not only increased the concentration gradient between α/IA, but also reduced the pitting resistance equivalent number (PREN) of original austenite (γ). Scanning Kelvin probe (SKP) and Gaussian fitting proved that with prolonged corrosion time, the potential difference enlarged and local corrosion aggravated. Measured by the weight loss method, pitting resistance decreased to one-third of the solid solution state due to the existence of IA; following, the quantities, sizes, and depth of corrosion pits increased significantly. In addition to α/γ boundaries and α/α boundaries, corrosion pits preferred to initiate around IA. The IA that appeared at α grain boundaries deteriorated the pitting corrosion resistance severely. Furthermore, original austenite with decreased PREN tended to be corroded. In general, the order of pitting occurrence is displayed as follows: α-γ-IA. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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24 pages, 5224 KiB

Open AccessArticle

Thermodynamic and Experimental Study on Migration Characteristics of Heavy Metals during the Melting Process of Incineration Fly Ash

by Yufeng Guo, Chen Gong, Lingzhi Yang, Ming Hu and Xun Hu

Metals 2022, 12(6), 1036; https://doi.org/10.3390/met12061036 - 17 Jun 2022

Cited by 3 | Viewed by 1655

Abstract

The migration characteristics of heavy metals during the melting process were one of the key factors for safe treatment and resource utilization of incineration fly ash (IFA). In this paper, the material variation of heavy metal elements of Pb, Zn, Cu, and Fe during the IFA melting process was simulated by HSC 6.0 chemistry software. The effects of melting temperature, alkalinity, atmosphere, chlorine content of raw materials, and an iron bath added to the migration characteristics, and phase transformation of selected heavy metal elements was investigated. The simulation results were also verified by experimental results. The results showed that, with the increase in temperature, the gas phase proportion of Pb, Zn, Cu, and Fe gradually increased. The alkalinity had little effect on the proportion of elements Fe and Cu in the liquid slag (LS) phase and the element Pb in the gas phase, but the increase in alkalinity could inhibit the proportion of element Zn in the gas phase. Zn mainly existed in the gas phase, and the atmosphere had little influence on the distribution of Zn. In reducing atmosphere (RA), elements Fe and Cu, which entered the liquid metal (LM) phase, were promoted, while the volatilization of Pb was restrained, which was conducive to the recovery of heavy metals. The melting process of IFA with water-washing and dechlorination had an inhibitory effect on the volatilization of Zn and Pb, but had little effect on Fe and Cu. The proportion of element Zn in the gas phase reduced from 85.84% to 9.89%. With the iron bath added in the IFA melting process, 98.42% of Cu and 82.28% of Pb entered the LM phase as metal simple substances, and 76.3% of Zn entered the gas phase as Zn (g) and ZnCl₂ (g). In the experimental verification, the distribution proportions of the four heavy metals in the gas phase, LS phase, and LM phase were consistent with the simulation results. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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28 pages, 20108 KiB

Open AccessArticle

Effect of Uniform and Non-Uniform Increasing Casting Flow Rate on Dispersion and Outflow Percentage of Tracers in Four Strand Tundishes under Strand Blockage Conditions

by Jinping Fan, Yuqian Li, Chao Chen, Xin Ouyang, Tianyang Wang and Wanming Lin

Metals 2022, 12(6), 1016; https://doi.org/10.3390/met12061016 - 15 Jun 2022

Cited by 12 | Viewed by 1701

Abstract

The flow field, tracer dispersion and uniformity of strands in two designs of four-strand tun-dishes under normal conditions and single-strand blockage conditions are studied by numerical simulation. The casting speed (flow rate) of strands are increasing uniformly or non-uniformly to improve the strand blockage condition. The uniformity of strands of the cases are evaluated by a novel outflow percentage analysis method. The results show that the flow field in the tundish does not change significantly when the single-strand is blocked or the casting flow rate is increased. After blockage of one strand, the consistency of each strand of u-shaped weir tundish is better than that of double-weir tundish. With the uniform increasing of the casting flow rate, the response time of each strand decreases and the outflow percentage increases. However, the uniformity of strands improved slightly in double-weir tundish but decreased in u-shaped tundish. For the double-weir tundish, significantly increasing the casting flow rate of the strand located in the blocked part by a factor of 1.5 and slightly increasing the casting flow rate of the other strands by a factor of 1.25, the consistency of each strand is the best. For the u-shaped weir tundish, the consistency of each strand is improved by non-uniform increasing of the casting flow rate of the strands. The flow rate of the strand located in the blocked part and the other strands is increased by a factor of 1.25, and 1.375 or 1.2 and 1.4 are the optimized cases. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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16 pages, 8773 KiB

Open AccessArticle

Influence of Nickel on Niobium Nitride Formation in As-Cast Stainless Steels

by Anže Bajželj, Barbara Šetina Batič, Jožef Medved and Jaka Burja

Metals 2022, 12(4), 609; https://doi.org/10.3390/met12040609 - 31 Mar 2022

Cited by 1 | Viewed by 2265

Abstract

The influence of the nickel content and cooling rate on niobium nitride precipitation in as-cast stainless steels were analysed. Niobium microalloying is important for mechanical properties and the prevention of intergranular corrosion in stainless steels. However, coarse precipitates can negatively affect steel properties. The precipitation of NbN depends on thermodynamic conditions, which are dictated by the chemical composition and temperature. The thermodynamic computations were used to estimate niobium nitride precipitation. Additionally, segregation models were used to predict precipitation. Three steel batches with different nickel contents (9 wt.%, 4.7 wt.%, and 0.16 wt.%) were prepared in an induction furnace and cast into sand moulds. The polished and etched samples were examined with an optical microscope, followed by a more detailed examination using a scanning electron microscope. An automatic scanning electron microscope analysis of the niobium particles was performed to obtain particle number and size distribution. Primary niobium carbonitrides, eutectic phases, and heterogenous nucleations on MnS inclusions were observed. As the proportion of nickel in the solution decreased, the solubility of nitrogen in the melt increased, which is manifested by a lower formation of primary and eutectic niobium carbonitrides, while MnS non-metallic inclusions played an important role in the heterogeneous nucleation. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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Review

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12 pages, 2280 KiB

Open AccessReview

Acoustic Analysis of Slag Foaming in the BOF

by Jason Heenatimulla, Geoffrey A. Brooks, Michelle Dunn, David Sly, Rod Snashall and Wang Leung

Metals 2022, 12(7), 1142; https://doi.org/10.3390/met12071142 - 5 Jul 2022

Cited by 8 | Viewed by 2839

Abstract

The control of slag foam that is produced during the Basic Oxygen Furnace (BOF) process has been the subject of significant research. The behaviour of slag foams is complex. Hence, the control of slag foam in the dynamic process of the BOF is challenging. Acoustic analysis of the BOF is one of the most promising methods for the indirect measurement of slag foam height. This paper reviews different studies on the fundamental behaviour of acoustics in liquid foams and various acoustic studies related to determining the slag foam height during the BOF process. Studies on the BOF have been carried out using both cold water models and plant trials, where acoustic measurements taken directly from the process were analysed. These studies showed that the attenuation of sound through liquid foam was influenced mainly by factors such as viscosity, bubble size, and foam height. Current systems are said to be 70 to 87 per cent accurate in detecting and/or predicting slopping events in the BOF, though there is a lack of systematic data in the literature to fully quantify this accuracy. There have been various attempts to combine sound with vibration and image signals to improve the prediction of slopping events in BOFs. The review substantiates the lack of accuracy of the current systems in determining the slag foam height using acoustic analysis and the need to address fundamental questions about the behaviour of sound in dynamic foam, its reliance on different factors, and the relatability of comparing cold model data to industrial data. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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21 pages, 4255 KiB

Open AccessReview

Study on the Characteristics of Coherent Supersonic Jet with Superheated Steam

by Xin Li, Guangsheng Wei, Rong Zhu, Bohan Tian, Ruimin Zhao and Xinyi Lan

Metals 2022, 12(5), 835; https://doi.org/10.3390/met12050835 - 13 May 2022

Cited by 5 | Viewed by 2266

Abstract

By establishing a mathematical model to simulate a mixed jet of oxygen and superheated steam from a coherent supersonic jet oxygen lance, we studied the effect of superheated steam on the fluid characteristics of the mixed jet. The model was initially verified through laboratory experiments prior to analyzing the fluid characteristics of the mixed jet in detail. These characteristics included the jet velocity, the temperature, the turbulent kinetic energy (TKE), and the mass distribution. The results showed that, at an ambient temperature of 1700 K, the jet velocity measured in the laboratory experiment was consistent with the fluid velocity obtained by numerical simulations, with an error of only 2.7%. In a high-temperature environment, the jet velocity of the mixed oxygen and superheated steam jet was increased, the TKE around the center jet was enhanced, the superheated steam exhibited an inhibitory effect on the combustion reaction of annular methane, and the potential core length of the coherent supersonic jet was reduced, which was conducive to methane combustion and delayed the reduction in the central jet velocity. Full article

(This article belongs to the Special Issue Clean Ironmaking and Steelmaking Processes)

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