Ferroalloy - FINAL TECHNICAL REPORT Project Title:...

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FINAL TECHNICAL REPORT Project Title: Development of a Process to Continuously Melt, Refine, and Cast High Quality Steel Award Number: DE-FC36-03ID14279 Project Period: May 1, 2003 – April 30, 2006 Date of Report: July 28, 2006 Principal Investigators: Kent D. Peaslee, 573-341-4714, kpeaslee@umr.edu Von L. Richards, David G.C. Robertson and Jeffrey D. Smith Recipient: University of Missouri – Rolla Department of Materials Science & Engineering 218 McNutt Hall, 1870 Miner Circle Rolla, MO 65409-0340 Subcontractors: University of Illinois at Urbana-Champaign Department of Mechanical and Industrial Engineering 140 Mechanical Engineering Building, MC-244, 1206 West Green Street Urbana, IL 61801 Point of Contract: Brian Thomas, 217-333-6919, bgthomas@uiuc.edu Other Partners: Bayou Steel, Nucor Steel, Nucor-Yamato Steel, SMI-Steel, TXI- Chaparral, Gerdau Ameristeel, Core Furnace Systems, Proware-Metsim, Heraeus Electronite
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Acknowledgment, Disclaimer and Proprietary Data Notice Acknowledgement: This report is based upon work supported by the U. S. Department of Energy under Award No. DE-FC36-03ID14279. Disclaimer: Any findings, opinions, and conclusions or recommendations expressed in this report are those of the authors and do not necessarily reflect the views of the Department of Energy.
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Table of Contents Report Section Page E x e c u t i v e S u m m a r y 1 Introduction and Background 2 Critical Literature Review of Continuous Steelmaking 4 Historic developments in continuous steelmaking research 5 Conclusions from the Literature 13 Use of Experimental and Theoretical Methods to Investigate Mixing in Gas Stirred Reactors 14 Experimental Procedure – Ladle Metallurgy Industrial Trials 14 Development of Computational Model 17 Development of Ferroalloy Model 20 Discussion of Ladle Metallurgy Experimental and Modeling Results 22 Ferroalloy Melting and Mixing 23 Summary of Findings from Gas-Stirred Reactor Mixing Studies 27 Use of Computational Fluid Dynamics to Simulate Continuous Steelmaking Vessels 28 Experimental Technique – Mathematical Formulations and Computational Conditions 28 Results – Fluid Flow and Particle Motions – No Argon Injection 31 Results – Fluid Flow and Particle Motions – With Argon Injection 32 Summary of Results from CFD Modeling of Continuous Steelmaking Vessels 40 Experimental Study of Steel Treatment to Model Continuous Steelmaking Kinetics 41 Experimental Procedure – Industrial Trials 41 Experimental Procedure – Metsim Thermodynamic and Kinetic Modeling 41 Discussion of Experimental Data and Simulation Results 44 Correlation Between the Mass Transfer Rate Constant and the Specific Stirring Power 47 Specific Steel Transport Rate 49 Thermodynamic Factors that Affect Reaction Rates 50 Apparent Reaction Order 52 Decarburization of the Steel During Argon Purging 53 Summary of Findings -Experimental Study of Reaction Kinetics in Industrial Reactors 55 Design of Novel, Scrap-Based, Fully Continuous Steelmaking Process 56 Description of Modified Consteel EAF (vessel 1) 58 Description of Oxidizer (vessel 2) 59 Description of Reducer (vessel 3) 61
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This note was uploaded on 10/08/2009 for the course CME MAT E 630 taught by Professor Dr. during the Fall '09 term at University of Alberta.

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Ferroalloy - FINAL TECHNICAL REPORT Project Title:...

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