Comprehensive kinetic and modelling study of basic oxygen steelmaking

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The Basic Oxygen Steelmaking (BOS) process is relatively mature and well understood in qualitative terms. However, optimizing operations has been based largely on a statistical models of process data and, although efficient in day to day operation generally limit control to known operating windows. Such models do not address several open questions regarding the detailed reaction mechanisms and the contributions from different reaction sites inside the Basic Oxygen Furnace (BOF). The overall objective of this project is to develop a comprehensive model of carbon, sulphur and phosphorus refining in a Basic Oxygen Furnace (BOF), based on our fundamental mechanistic knowledge of all critical aspects of the process. The research caps several years of related developments by the applicants concerning refining rates in slag-metal emulsions, and will be done in collaboration with Canadian and global steel industry partners. The research will combine detailed experimental studies of high temperature kinetics, which will answer fundamental scientific questions about the behaviour of droplets in the (BOF), with a holistic modeling approach which will be refined and ultimately validated using data from industrial trials. By comparison of overall steel bath refining with that due to droplets alone, as well as comparison of reactions which are site specific with those which may occur at multiple sites, the relative contributions of droplets and the so called "hot spot" will be determined. All of this information will be combined with slag formation data from plant sampling, to develop a comprehensive model of the BOF. Canada currently produces approximately 13 million tonnes of steel per year with over half produced in five BOF vessels. The current proposal will improve the efficiency of BOF steelmaking in terms of cost, yield and energy efficiency per tonne of steel. The direct participation of a Canadian producer and availability of the results for application more widely will afford Canadian steelmakers cost and quality advantages.