Teacher Guide 1

This set of guides has been prepared for steeluniversity.org ambassadors and approved teachers and trainers to help in using the website resources in a range of teaching and learning scenarios. They are not intended for general release to the public and on no account should electronic versions be posted on publicly-accessible websites or fileservers. 1. Basic Solutions for All Four Grades in EAF and Secondary Steelmaking Simulations These are suggested production routes that Teachers/Demonstrators can use. They should lead to a successful result (at University Student level), although this will not be the best (least cost) solution. 2. Production Solutions for the Linepipe Steel Grade in BOF, EAF, Secondary Steelmaking and Continuous Casting Simulations These are suggested production routes for a single grade through several different steelmaking simulations which are, or will soon be, linked. Note: Suggested additions for secondary steelmaking will need to be re-calculated if the simulations are linked (using a saved cast from EAF/BOF) rather than run as standalone. 3. Suggestions for Using Steelmaking Simulations with Adults and Children Case studies and materials (recipes, equipment requirements, certificates etc.) for running simulations and/or steelmaking challenges with different age groups. If you have any feedback regarding this guide, please get in touch via the contact page at www.steeluniversity.org.

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Teacher Guide

Basic Solutions for All Four Grades in Electric Arc Furnace and Secondary Steelmaking Simulations

1 2 3 4

Purpose of this Guide.............................................................................. 1 Format of Suggested Route ...................................................................... 1 Electric Arc Furnace Simulation................................................................. 2 Secondary Steelmaking Simulation ............................................................ 4 4.1 General Purpose Construction Steel........................................................4 4.2 TiNb Ultra-low carbon steel for galvanized auto body ....................................6 4.3 Linepipe Steel for Gas Distribution ..........................................................8 4.4 AISI 4010 Engineering steel ............................................................... 10

Purpose of this Guide

This guide is designed to give demonstrators suggested additions and production routes that will allow the Electric Arc Furnace (EAF) and Secondary Steelmaking (SSM) simulations to be completed as standalone for each of the four pre-set grades featured. It does not cover suggestions for any customized alloy compositions that may be added to the simulation manually or linked production in the SSM simulation using a cast saved previously in the EAF. It should be noted that although these suggested routes, if followed correctly, will give a successful simulation result, this will not necessarily be the best (i.e. most cost-effective) solution.

Format of Suggested Route

EAF Suggested scrap additions are given for the selected alloy. The user will need to divide these up into appropriate loads for each basket for charging to the furnace. Where appropriate, suggestions for further additions, e.g. to make a foaming slag, are given. SSM Each suggested route details the typical tapping composition and the aim composition for the selected alloy, followed by a series of steps including the route around the plant equipment and alloy additions. There are not the only possible routes and the exact additions and process conditions will depend on the starting composition that the simulation presents each time it is started.

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Electric Arc Furnace Simulation

Picture Description Predominantly 6 mm thick, in sizes not exceeding 1.50 m 0.60 m 0.60 m (or as otherwise agreed) prepared in a manner to ensure compact charging. May include tube and hollow section, wire rope properly prepared by agreement with consumer, properly prepared material from heavy commercial vehicles including wheels, but excluding body and wheels from light vehicles. Predominantly 3 mm thick, in sizes not exceeding 1 m 0.60 m 0.60 m (or as otherwise agreed) prepared in a manner to ensure compact charging. May include properly prepared material from dismantled vehicles including light vehicle wheels, but must exclude vehicle body arisings and also domestic appliances. Scrap accumulated within the steel works that has no more than a total of 5 wt-% of alloying elements and no more than 1 wt-% carbon content. Size and shape varies but is usually compressed to ensure easy charging. Consists of cut structural and plate arisings predominantly 6 mm thick in sizes not exceeding 1.50 m 0.60 m 0.60 m (or as otherwise agreed) prepared in a manner to ensure compact charging. May include properly prepared wagon material less than 6 mm thick. Excludes tube and hollow section. New black steel sheet scrap, clippings or skeleton scrap, compressed or hand bundled, to charging box size, and weighing not less than 75 pounds per cubic foot. (Hand bundles are tightly secured for handling with a magnet.) May include Stanley balls or mandrel wound bundles or skeleton reels, tightly secured. May include chemically detinned material. May not include old auto body or Possible mix / tonnes CON ULC LPS* ENG

Scrap Type

No1 Heavy

20

No2 Heavy

40

Internal Low Alloyed

No picture

Plate and Structural

No1 Bundles

30

42

50

20

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Scrap Type

Picture

Description fender stock. Free of metal coated, limed, vitreous enameled, and electrical sheet containing over 0.5 wt-% Si. Old black and galvanized steel sheet scrap, hydraulically compressed to charging box size and weighing not less than 75 pounds per cubic foot. May not include tin or lead-coated material or vitreous enameled material.

Possible mix / tonnes CON ULC LPS* ENG

No2 Bundles

30

40

30

20

Also known as direct reduced iron, is a virgin iron source that is relatively uniform in composition, and virtually free from tramp elements. It is increasingly used in EAF DRI steelmaking to dilute contaminants present in the steel scrap. It contains a certain amount, roughly 2 wt-%, of carbon which serves as an additional energy source. DRI can be produced in different ways and the two most common processes are Midrex and HYL. Old light steel arisings fragmentized into pieces not exceeding 200 mm in any direction. Must be free from dirt, free from non-ferrous metals and foreign material and exclude excessive moisture, introduced loose cast Shredded 10 5 10 iron, incinerator material, grindings, swarf, turnings and borings. Should also be free from tin cans. Must conform to the following specifications: minimum density of 0.80 tonne per m, maximum content of Sn and Cu of 0.03 wt-% and 0.25 wt-%, respectively. * All mixtures result in P levels in excess of target maximum. The P composition must be decreased after melting is complete, but prior to heating by injecting O2 at 150 Nm3 min-1 for ~15 min.

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4.1

Secondary Steelmaking Simulation

General Purpose Construction Steel Cast size: ~100 tonnes Required inclusion level: Moderate Time to caster: 6080 minutes Temperature at caster: 15301540 C Caster: Bloom Typical cost: $20.00/tonne

Table 1 Typical composition data for the construction grade steel

C Si Mn P S Cr Al B Ni Cu Sn Nb Ti V Mo N H O

Tap ~0.0500 ~0.0000 ~0.1200 ~0.0170 ~0.0150 ~0.0100 ~0.0000 ~0.0001 ~0.0100 ~0.0100 ~0.0050 ~0.0000 ~0.0000 ~0.0000 ~0.0020 ~0.0030 ~0.0003 ~0.0400

Aim 0.1450 0.2000 1.4000 0.0350 0.0420 -

Min 0.1300 0.1500 1.3000 0.0250 0.0350 -

Max 0.1600 0.2500 1.5000 0.0250 0.0200 0.1000 0.0450 0.0005 0.1500 0.1500 0.0300 0.0500 0.0100 0.0100 0.0400 0.0050 0.0005 0.0010

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Table 2 Suggested process route for the construction grade steel

Start simulation No synthetic slag Add 120 kg Aluminum pebbles Start tapping the furnace After tapping stops, move the ladle car out 2 stops Pick up the ladle with the crane and transport to the CAS-OB Lower CAS-OB lid - do not use oxygen blowing Add 1700 kg High Carbon FerroManganese Only needed for linepipe steels This removes the oxygen from the molten steel Pour the molten steel out of the furnace into a transfer ladle

CAS-OB allows expensive additions to be made in a protective environment Manganese helps to strengthen the steel, but decreases ductility and weldability. It also helps to remove oxygen from the molten steel

Add 300 kg High Purity FerroManganese Add 270 kg Ferro-Silicon 75 Add 66 kg Ferro-Niobium

Silicon helps to remove oxygen from the molten steel Small amounts of Nb can significantly increase the yield strength AND toughness of steels by helping reduce the grain size Stirs the additions into the steel to make a uniform composition and temperature. Also accelerates cooling.

After adding, set the argon flow rate to the maximum setting (1.00) and continue in the CAS-OB for approx 5 minutes Stop CAS-OB Move ladle out into the casting area WAIT watch the time and temperature Pick up the ladle with the crane Move to bloom caster Wait until the required time At the required time the temperature should be with the required range Drop the ladle onto the caster using the crane

Under normal conditions the steel cools at ~0.5 C per minute.

The cast bloom will be hot-rolled into an I-beam in a Universal Beam mill

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4.2

TiNb Ultra-low carbon steel for galvanized auto body Cast size: ~250 tonnes Required inclusion level: Very low Time to caster: 7090 minutes Temperature at caster: 15551565 C Caster: Slab Typical cost: $17.00/tonne

Table 3 Typical composition data for the ultra-low carbon grade steel

Tap C Si Mn P S Cr Al B Ni Cu Sn Nb Ti Mo As N H O ~0.0300 ~0.0000 ~0.1000 ~0.0080 ~0.0100 ~0.0100 ~0.0000 ~0.0001 ~0.0100 ~0.0100 ~0.0050 ~0.0000 ~0.0000 ~0.0020 ~0.0020 ~0.0020 ~0.0003 ~0.0600

Aim 0.0030 0.2100 0.7500 0.0450 0.0009 0.0100 0.0100 -

Min 0.0020 0.1500 0.6500 0.0300 0.0006 0.0050 0.0050 -

Max 0.0040 0.2500 0.8500 0.0100 0.0120 0.0500 0.0550 0.0012 0.0800 0.0800 0.0100 0.0150 0.0150 0.0100 0.0100 0.0050 0.0005 0.0005

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Table 4 Suggested process route for the ultra low carbon grade steel

Start simulation No synthetic slag DO NOT DEOXIDIZE the oxygen is required for decarburization Start tapping the furnace After tapping stops, move the ladle car out 2 stops Pick up the ladle with the crane and transport to the recirculating degasser

Usually steel is deoxidized early, but not in this case

Removes carbon allowing it to react with oxygen to form CO (carbon monoxide) then removing this gas

Lower the unit, do not use oxygenblowing Degas for 15 minutes With unit still lowered add 210 kg aluminum to deoxidize Wait 5 minutes for deoxidation to complete Add 3490 kg Ferro-Manganese High Purity

After carbon is removed, add aluminum to deoxidize.

Manganese helps to strengthen the steel, but decreases ductility and weldability. It also helps to remove oxygen from the molten steel. Normal ferro-manganese has too much carbon, so need high purity (expensive)

Add 720 kg Ferro-Silicon 75 High Purity Add 11 kg Ferro-Boron Add 40 kg Ferro-Niobium

Small amounts of Nb can significantly increase the yield strength AND toughness of steels by helping reduce the grain size Used to achieve low grain size, high strength and toughness

Add 25 kg Titanium Allow at least 15 minutes for the additions to mix Move the ladle out into the casting area WAIT watch the time and temperature Pick the ladle up with the crane Move to the slab caster Wait until the required time At the required time the temperature should be with the required range Drop the ladle onto the caster using the crane

The cast slab will be hot-, then cold-rolled to thin strip (<1 mm), coated with zinc (galvanized) and pressed into car body panels

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4.3

Linepipe Steel for Gas Distribution Cast size: ~250 tonnes Required inclusion level: Very low Time to caster: 80120 minutes Temperature at caster: 15271552 C Caster: Slab Typical cost: $25.00/tonne

Table 5 Typical composition data for the linepipe grade steel

Tap C Si Mn P S Cr Al B Ni Cu Sn Nb Ti V Mo Ca N H O ~0.0500 ~0.0000 ~0.1200 ~0.0070 ~0.0080 ~0.0100 ~0.0000 ~0.0001 ~0.0100 ~0.0100 ~0.0050 ~0.0000 ~0.0000 ~0.0000 ~0.0020 ~0.0000 ~0.0030 ~0.0004 ~0.0400

Aim 0.0700 0.1800 1.0500 0.0300 0.0150 -

Min 0.0600 0.1300 1.0000 0.0250 0.0120 0.0010 -

Max 0.0800 0.2300 1.1000 0.0080 0.0030 0.0600 0.0350 0.0050 0.0500 0.0600 0.0150 0.0180 0.0100 0.0100 0.0100 0.0050 0.0045 0.0002 0.0007

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Table 6 Suggested process route for the linepipe grade steel

Start simulation Select maximum slag composition (45% CaO) Select 2800 kg synthetic slag

The slag acts as a liquid sponge that will draw the sulfur out of the molten steel Removes oxygen from the steel

Start tapping the furnace Add 300kg Aluminum pebbles IMMEDIATELY After tapping stops, move the ladle car out 2 stops Pick up the ladle with the crane and transport to the ladle furnace Do not use any power or stirring Add 50 kg Recarburizer Add 5000 kg Ferro-Manganese High Purity Add 610 kg Ferro-Silicon 75 Add 60 kg Ferro-Niobium

Small amounts of Nb can significantly increase the yield strength AND toughness of steels by helping reduce the grain size Helps to control sulfur Sulfur removal is more efficient at higher temperatures

Add 100 kg Calcium-Silicon Powder Heat on full power to 1625 C Raise the ladle furnace lid Transport the ladle car back towards the tank degasser Cover the tank and select the maximum vacuum and argon flow rate

Vacuum helps remove damaging hydrogen. Intense stirring helps mix the slag and molten steel in order to remove the sulfur.

Degas for 30 minutes Uncover the tank Transport the ladle to the slab caster WAIT watch the time and temperature At the required time the temperature should be with the required range Drop the ladle onto the caster using the crane

The slab will be controlled-rolled into plate several mm thick. The plates are then shaped in U and O presses to make a circle, then submerged-arc welded to form a pipe.

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4.4

AISI 4010 Engineering steel Cast size: ~100 tonnes Required inclusion level: Low Time to caster: 70120 minutes Temperature at caster: 15581578 C Caster: Billet Typical cost: $65.00/tonne

Table 7 Typical composition data for the engineering steel

Tap C Si Mn P S Cr Al B Ni Cu Sn V Mo N H O ~0.1300 ~0.0060 ~0.1200 ~0.0070 ~0.0080 ~0.0100 ~0.0000 ~0.0001 ~0.1000 ~0.0100 ~0.0050 ~0.0000 ~0.0020 ~0.0030 ~0.0004 ~0.0400

Aim -

Min 0.3800 0.6000 0.9000 0.0150 0.1500 -

Max 0.4500 0.4000 0.9000 0.0350 0.0350 1.2000 0.0300 0.0050 0.3000 0.3500 0.0400 0.0100 0.3000 0.0050 0.0003 0.0005

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