In the transition to green steelmaking, hybrid steel plants incorporating both EAF and BOF technologies face several critical logistical challenges. Different tap-to-tap times, variations in steel chemistries and temperatures, the positioning of new equipment, and integration with existing plant infrastructure significantly impact ladle logistics. Inefficient ladle flow and overutilized cranes...
In electric smelting furnaces, a carbon source functions as both a reducing agent and a carburizer. Carbon bio-sources, namely biochar, offer an alternative to fossil carbon sources but differ in properties and reactivity. Reactivity is a complex characteristic and requires considering properties such as volatile matters (VM), ash and mineral matters, fixed carbon (FC), specific surface area...
In a converter process, foaming slag has advantages in that it facilitates intermediate deslagging and protects refractory materials in the furnace. On the other hand, in an electric arc furnace process, foaming slag improves the arc heat transfer efficiency by acting as an insulator. In both steelmaking processes, slag foaming is important. In the slag, there are suspended particles of iron...
The transformation towards climate neutrality is one of the most urgent topics for steel producers and research facilities. One of the pillars to drastically reduce greenhouse gas emissions is increased recycling of steel scrap in EAFs. Unfortunately, various tramp elements are not removable from melts and accumulate over recycling cycles which often leads to scrap exports and downcycling to...
A fully comprehensive process transformation from a conventional integrated steel mill with blast furnace and converter to a modern electric steel mill with the aim of drastically reducing CO2 emissions involves many dangers and requires a precise weighing of all possible solution variants, including their effects on both productivity and the steel grades to be produced.
This article...
Hydrogen-based direct reduction combined with a two-step process employing a Smelter and a BOF is the most promising green steel production route using low-grade iron ores. As the BOF is still operated in this new route, todays and future crude steel quality requirements can be fully met. The hot metal from the Smelter is similar to the blast furnace one, with slightly lower carbon and silicon...
The ongoing transformation of steel production to Green Steel making is a demanding and collaborative effort involving various stakeholders, including steel producers, Original Equipment Manufacturers (OEMs) and technology providers to overcome technical and economic challenges. For example, the upscaling of Electric Arc Furnaces (EAF) with tapping weights exceeding 250 tonnes and more complex...
With the ongoing efforts to reduce the CO2 emissions of the iron and steel industry the importance of the electric arc furnace (EAF) significantly increased. While in 2020 only 36% of the announced steelmaking capacity used an EAF based route in 2023 it was already 92%. With the shift towards an EAF based steel industry, the question remains, how the typical product mixes from the blast...
Monolithic linings for steel ladles have emerged as a economically and ecologically sustainable alternative to traditional bricked based linings.
This lining method offer several advantages, including enhanced durability, reduced material waste, improved thermal insulation, and reduced maintenance costs as well as an essential impact on heat management and CO2 greenhouse emission in the...
The transition to carbon-free steel production presents significant challenges for steel manufacturers, particularly in adapting to new process timelines, routes, and transport logistics. The shift from the conventional integrated plant based on Blast Furnace (BF) operation and Basic Oxygen Furnace (BOF) process to electric steel production entails substantial changes in secondary metallurgy...
The Electric Arc Furnace (EAF) has become a cornerstone of modern steel production, accounting for over 43% of Europe's output. Despite its widespread adoptionseveral aspects of the furnace are operated and optimized empirically due to the extreme conditions within the furnace. Numerical modelling provides a valuable approach to bridge this gap by simulating arc behaviour and its interactions,...
Electric arc furnace steelmaking is an important way to bring carbon neutrality to the steel industry by 2050 because the blast furnace and basic oxygen furnace processes release the higher CO2 emissions than the EAF process. However, as the heat generated by the arc affects the upper part of the molten steel locally, the stirring energy of the EAF molten steel is insufficient to achieve the...
