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CHAPTER 9

RESULTS

Bonestell and Weber (1985) have mentioned about predictability

of end point carbon in EOF. They have stated that approximate drop of carbon
was 0.15 % per minute up to 0.05% carbon. They have not carried out very
detailed work on “Catch Carbon Process”. During mid 80’s, the main focus
in EOF was to make it operationally viable and to achieve good thermal
balance in liquid steel for subsequent processing, which was usually without a
ladle furnace. Hence, more efforts were put to get end temperature at the time
of tapping rather than end carbon. In the field of EOF, detailed work on
“Catch carbon process” has been carried out in the present research work for
the first time.

Through implementation of “catch carbon process”, it was

established that heats could be tapped from EOF with percent carbon in the
bath above 0.10% on consistent basis as elaborated in the preceding chapter 8.
The most important result of the catch carbon process experiment was that
there was a very close correlation between drop of carbon in the bath and total
oxygen consumed through tuyeres and atmospheric injectors. Based on the
carbon content in S2 sample, the EOF operator had to control total oxygen
consumed through tuyeres and atmospheric injectors until tapping of the steel.
Software program was installed in the EOF computer in which, based on S2
sample results, the operator had to punch final carbon desired after tapping of
steel. The computer MMI displayed the balance carbon to be consumed on a
continuous basis and this helped in achieving carbon percentage in the bath
above 0.10% on a consistent basis.
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The catch carbon experiments also gave a very important finding

that there was poor relation between drop of carbon and time in the EOF as
shown in Figure 8.7. Prior to this work, usual practice in EOF was to control
the final carbon percentage in the steel bath mostly based on time. This was
very important result achieved in the present research work.

The direct benefits from catch carbon process were established in

the heats where tapping carbon was above 0.10%. The savings were
calculated for the ferro alloys and improvement in liquid metal yield
percentage.

9.1 IMPROVEMENT IN SILICON RECOVERY

Figure 9.1 shows the improvement in silicon recovery with increase

in tapping carbon.

% TAP CARBON

Figure 9.1 Improvement of silicon recovery with opening carbon

9.2 SAVINGS IN LOW CARBON STEELS

The savings in the TMT grade, which were realized through catch
carbon process, are shown in Table 9.1.
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Table 9.1 Savings in TMT grade through catch carbon process

Saving in Value in
Sl. No. Ferro Alloy
Kg/MT Rs/MT
(i) FeSi 1.13 48.60
(ii) SiMn 0.37 13.50
(iii) CPC 0.88 13.20

Savings due to 1% higher liquid metal yield 120.00

Total Savings 195.30

9.3 SAVINGS IN MEDIUM CARBON STEELS

The savings in medium carbon, spring steel grade SUP-9 through

catch carbon process are shown in Table 9.2.

Table 9.2 Savings in medium carbon, spring steel grade through catch
carbon process

Saving in Value in
Sl.No. Ferro Alloy
Kg/MT Rs/MT
(i) FeSi 0.93 40.00
(ii) SiMn 0.79 28.80
(iii) Graphite Fines 1.92 51.40
(iv) Al Ingots 0.05 7.00
(v) Fe-Al 1.19 92.50
(vi) Ca-Si Wire 0.018 2.30
Savings due to 1% higher Liquid Metal Yield 84.00
Total Saving 306.00
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The implementation of the catch carbon process in the EOF is a

major milestone in steel making. As presented, if the steel is tapped from the
EOF above 0.1% carbon, and as close to the final carbon specified, it helps to
improve charge to liquid metal yield, blowing time, refractory consumption
and ferro alloys consumption. Savings only on account of ferro alloys
consumption and yield improvement is (Rs.200 to 300) per MT depending on
the steel grade. The implementation of catch carbon in the EOF would be a
step forward with regard to its competitive steel making process viz., LD
converter.

9.4 IMPROVEMENT IN BLOWING TIME IN EOF

The average blowing time reduced from 36 min per heat to 31 min
per heat, which gave rise to 14% increase in productivity.

9.5 IMPROVEMENT IN REFRACTORY CONSUMPTION IN

EOF

The total refractory consumption is reduced by 2.3 kg/MT, which

correspond to Rs.100 per MT cost reduction.

9.6 IMPROVEMENT IN STEEL QUALITY

The catch carbon process improves the tapping carbon above

0.10 %. The oxygen ppm in the semi finished steel tapped from EOF is lower
which helps in subsequent refining of steel in ladle furnace and vacuum
degassing. Hence catch carbon process, not only speeds up the secondary
refining process, but also helps to produce superior quality steel. The
de-sulphurization is better resulting in lower sulphur level in finished steel.
The steel produced is cleaner with regard to non-metallic inclusions and gas
levels.