Thermodynamic studies of slags with respect to foaming in electric arc furnace

Roberto R. de Avillez 1, André Costa e Silva 2 and Raimundo A. F. O. Fortes 3

DEMa-PUC RJ, 22451-900 Rio de Janeiro, RJ – Brazil 1
EEIMVR-UFF, 27260-740 Volta Redonda, RJ – Brazi 2l
Gerdau Aços Longos Brasil S.A., Av.Joao XXIII, 23560-900 Rio de Janeiro, RJ – Brazil 3

Abstract Effective Viscosity

Electric arc furnace (EAF) steelmaking relies heavily on slag
foaming properties to operate efficiently with long arcs. Slag
foaming allows for the use of a thick slag layer without increasing
the slag weight. This improves thermal efficiency, decreases
melting time and lowers both refractory and electrode consumption.
Foaming is produced by the reduction of slag FeO with injected
carbon. Electric furnaces slags are basic slags, highly oxidized and
normally saturated or close to saturation with MgO, an important
component of the slag refractories. It has been demonstrated that,
besides having adequate viscosity and surface tension, slags with a
small volume fraction of solid second phase particles, are the ones
with the best foaming stability conditions.
The presence of second phase particles in the slag, fraction
f , changes the viscosity of the slag. These particles are
considered essential to form a foamy slag.
E. B. Pretorius and R. C. Carlisle, Foamy slag fundamentals and their
practical applications to electric furnace steelmaking, 1988 Electric
Furnace Conference Proceedings, p. 275-292, 1988.
ηe
= (1 − 1.35 f ) −2.5
η

In this work, the conditions for the precipitation of a small amount

of magnesia-wustite in the relevant slag system are calculated. The
effect of changes in slag composition and temperature on the
amount of magnesia-wustite precipitated are discussed and the
results are used to estimate the effective viscosity of the slag. Isothermal Phase Diagram, 1600°C
Control diagrams for use in the melt shop, based on isothermal
cross-sections of the pseudo-ternary phase diagrams, MgO-SiO2- w(CaO)
Basicity, B3= = 1.5
FeO, are also proposed. w( SiO2 )

Foams and Emulsions in Steel Making

• Several steelmaking processes depend on formation and foams

and emulsions for their efficiencies.
• Top blown Converters promote fast reactions through the
formation of na emulsion- and the control of its stability is a
critical operational problem
• Smelting processes proposed as future routes for iron- and
steelmaking in general depend on emulsions for kinetic Calculated Slag Base, Experimental, Apud Pretorius
reasons. Thermo-Calc S and Carlisle, 1988
• The modern electric arc furnace depends on a “foamy slag” for
its efficiency.
Slag Saturated with (Mg,Fe)O at 1600°C
The region where (Mg,Fe)O – magnesiowustite, MW,
The Importance of a Foamy Slag for
is present is considered, by the EAF operators as a
Electric Arc Furnace good region for the balance of EAF operations.
0.030
• Allows the use of long arcs with high voltage and lower currents (Mg,Fe)O 0.00
0.7
X(FeO), MW=0.00
(Mg,Fe)O 0.04 X(CaO), MW=0.00
thus: 0.025
(Mg,Fe)O 0.06
(Mg,Fe)O 0.04 effective
Molar Fraction in Slag 0.6 X(FeO), MW=0.04
X(CaO), MW=0.04
(Mg,Fe)O 0.06 effective X(FeO), MW=0.06
0.020
– Reducing electrode size and consumption by oxidation 0.5
Viscosity, Pa.s

X(CaO), MW=0.06

0.015 0.4
• Improves thermal efficiency and protects furnace walls
(refractories or water cooled panels). 0.010 0.3

0.005 Temperature 1600 °C 0.2

– As a consequence decreases melting time, increase efficiency Temperature 1600 °C

and decrease total cost per ton. 0.000

0.06 0.07 0.08 0.09 0.10
0.1
0.06 0.07 0.08 0.09 0.10
Mass Fraction MgO Mass Fraction MgO

Viscosity as a function of theMolar Fraction of FeO and

The Challenge
• Achieve good slag “foaming” behavior, maintaining:
– A good basicity for de-P and silica retention
– An adequate fluidity for slag removal from furnace
– Chemical compatibility (as much as possible) with
refractories
– Low cost (total foam volume and foaming behavior
also define total slag weight needed!)
total MgO for basicity B3=1.5 CaO in Slag as a function of
the total MgO for basicity
B3=1.5
The above plots were calculated for MgO saturated slags
with different fractions of precipitated magnesiowustite.
MW=0 shows the solubility limit.
Increasing the MgO content of the slag increases the
viscosity even for a slag without precipitated (Mg,Fe)O (solid
black line).

Foaming Index, Σ The major effect of the (Mg,Fe)O precipitation is to change

the slag content of FeO and CaO to keep the constant
Foaming indexes have been proposed from dimensional analysis basicity.
of the system.
μ 1.2
0.08

Y. Zhang and R. J. Fruehan: Metall. Mater.

Σ = 115
0.32
25 FeO, B=1.5

Trans. B., 26B (1995), 803.

FeO Molar Fraction in Slag

σ 0.2 ρDb0.9
25 FeO, B=1.5
Effective Viscosity, Pa.s

25 FeO, B=2.0
25 FeO, B=2.0 30 FeO, B=1.5
0.06
30 FeO, B=1.5 0.28 30 FeO, B=2.0
30 FeO, B=2,0

μ H. S. Kim, D. J. Ming
Σ = 214
0.24
CaO Based Slags and J. H. Park, ISIJ
0.04

σρ 0.20

μ MgO saturated slags International, 41(4),

Σ = 999
0.02
317-324, 2001.
o o
Temperature 1600 C 0.16 Temperature 1600 C

σρ 0.0 0.1
Mass Fraction MgO
0.2 0.00 0.05 0.10
Mass Fraction MgO
0.15 0.20

Slag Viscosity (one possibility) Viscosity as a function of the Molar Fraction of FeO in Slag
total MgO for two basicities as a function of the total
Slag viscosity has been modeled in several different ways. and two total molar fraction of MgO for two basicities and
In special, the temperature effect has been observed in FeO two total molar fraction of
some systems to be “non-Arrhenius”. FeO.
A reasonable empirical approach has been proposed by
The above plots show that the slag viscosity does not depend
Riboud and colaborators at IRSID (ARSA, today).
very much on the total MgO content for the used basicities
B and FeO content, even though the FeO content in the slag
η = A.T . exp Pa.s
T changes as a function of the total MgO.
B = 31140 − 23896( X CaO + X FeO + X MgO + X MnO )
− 46356 X CaF2 − 39519( X Na2O + X K 2O ) + 68833 X Al2O3
Conclusions
ln A = −19.81 + 1.73( X CaO + X FeO + X MgO + X MnO ) Foaming in slags is a important phenomena in steelmaking;
+ 5.82 X CaF2 + 7.02( X Na2O + X K 2O ) − 35.76 X Al2O3 it is, however, a complex problem, involving the interaction
Paul V. Riboud, Y. Roux, Louis-Didier Lucas and Henri Gaye,
of slag phase equilibrium, solid phase fraction and viscosity
Improvement of Continuous Casting Powders, Fachberichte as well as surface tension.
Hüttenpraxis Metallveiterverarbeitung,19 (10), p. 859-869, 1981. Computational thermodynamics modeling can help predict
ideal conditions for foaming in Electric Arc Furnace slags, an
essential condition for efficient operation.
Currently, the main limitations seem to be on the viscosity
model used and on how to properly account for surface
tension in the foaming model.
The present model, coupling the Kapoor-Frohberg-Gaye
Acknowledgements model in Thermo-calc and the Riboud viscosity model will be
tested in EAF melt shops to check its usefulness.
To CNPq for continued support.