Simulating the Steelmaking and -Refining Process using Thermo-Calc’s Process Metallurgy Module

Simulating the Steelmaking and -Refining Process using Thermo-Calc’s Process Metallurgy Module

The Process Metallurgy Module (PMM) is a powerful addition to the Thermo-Calc Software suite. It comes together with the TCOX database and calculates isothermal or adiabatic equilibrium between multicomponent liquid or solid steel, slag, and refractory materials. Additionally, models to describe the reaction kinetics between liquid steel and slag have been implemented, allowing full kinetic simulations of real industrial steelmaking and -refining processes. Actual process parameters are used as input for the simulation, such as timing and amounts of additions (scrap, DRI, hot metal, ferro-alloy, flux, wire, and so on), timing and flow rates of gas, electric arc power, and power-on times. A few kinetic parameters that depend on size, geometry, and type of the steelmaking equipment must be fitted using experimental results from steel and slag sampling. The simulation then predicts the evolution of the steel and slag chemistry, evolution of thermophysical properties of the slag (such as viscosity, fraction liquid, basicity, the types and amounts of inclusions, temperature, off-gas amount, and composition), and more.

The PMM is a powerful tool for optimizing existing steelmaking and refining practices and developing recipes for new steel grades or alternative raw materials. Currently the functionality of the PMM is being implemented into TC-Python, which will allow automated setting up and running of process simulations. This will allow high trough-put parameter studies to find the optimal process window, or it would allow directly using steel plant level 2 data to run the Process simulation in parallel with day-to-day production, thereby realizing a digital twin of the steelmaking and -refining process.

In this webinar, an overview of the applications of Thermo-Calc to steelmaking and steel refining using the Process Metallurgy Module and the TCOX thermodynamic database for oxides and slags is given. Additionally, details of the most recent developments, and an outlook on what will soon be coming are discussed.

Speaker: Nicholas Grundy, Technical Sales Manager, Thermo-Calc Software

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Dr. Nicholas Grundy
Technical Sales Manager
Thermo-Calc Software AB

About the Speaker

Nicholas Grundy did his Ph.D. on CALPHAD database development of oxide materials at ETH in Zurich using Thermo-Calc Software and a Post Doc on slag phase diagrams and slag viscosity using FactSage at Ecole Polytechnique under Prof. Arthur Pelton. He then worked for almost 10 years in the steel industry for the SMS group as a metallurgist designing and commissioning steel plants all over the world.

In 2018 he joined Thermo-Calc Software, where he is using his shop-floor experience to support the development of models for steelmaking and refining that are based on CALPHAD type thermodynamic databases.

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