EP4056721A1 - Method for producing a ferrous alloy with low carbon content - Google Patents

Abstract

The invention relates to a method for producing a ferroalloy with a low carbon content, in particular a chromium alloy or a manganese alloy with a carbon content of less than 0.1%, in which the ferroalloy is first melted in a converter process by addition is treated with oxygen and the melt prepared in this way is then decarburized in a subsequent vacuum process. In order to shorten the treatment time of the melt and also to reduce the consumption of the required input materials, the invention provides that the melt is added to the melt before the end of the converter process to form slag, with no reduction in the converter process of the slag takes place, and that the slag is only reduced in the subsequent vacuum process.

Description

The invention relates to a method for producing a ferroalloy with a low carbon content, in particular a chromium alloy or a manganese alloy with a carbon content of less than 0.1%, in which the ferroalloy is first melted in a converter process by addition is primarily decarburized and treated by oxygen and then in a subsequent vacuum process the melt prepared in this way is refined to the deep carbon.

Such a method is from EP 2 986 743 B1 known. A vacuum converter is used here, in which a main decarburization of the melt takes place in a first stage, with oxygen being blown in via a top lance; then, in a second stage, deep decarburization takes place in the same converter under vacuum.

Further solutions, which are related to the present procedure, are from EP 2 878 684 B1 , from the WO 2006/050963 A2 , from the DE 10 2014 215 669 A1 , from the EP 2 207 905 B1 , from the EP 1 431 404 B1 and from the DE 10 2014 221 397 A1 known.

The conventional converter process in combination with a subsequent vacuum process is a technology for the production of stainless and high-alloy steel grades that are characterized by an extremely low carbon content. It includes the production of austenitic, ferritic and duplex steel grades including all derivatives with a carbon content of less than 0.015%. Process lines (such as the AOD-VOD process or the MRP-VOD process) use this technology. Also known as Triplex. In this respect, we expressly refer to the above EP 2 986 743 B1 the applicant referred.

In a conventional converter and vacuum process, such as in the mentioned EP 2 986 743 B1 described, the process ends metallurgically with a reduction of the slag formed during the carbon refining process. The technology consists of the following treatment phases: decarburization to thermodynamic carbon equilibrium, slag reduction, tapping, deslagging and further decarburization of the melt under vacuum. The continuation of the decarburization in the vacuum vessel then takes place with a slag-free metal surface and a vacuum of approx. 100 mbar and a short post-evacuation (VCD - Vacuum Carbon Degassing) at approx. 1 mbar.

$$\left(X_n{O}_m\right)+\frac{2m}{3}\left[\mathit{Al}\right]=n\left[X\right]+\frac{m}{3}\left\{{\mathit{Al}}_2{O}_3\right\}$$

In the case of the method described at the outset, this concludes with the slag reduction for the purpose of setting the desired properties (according to the target analysis). In general, the reduction proceeds according to the following equations (1) and (2): $$\left(X_n{O}_m\right)+\frac{m}{2}\left[\mathit{si}\right]=n\left[X\right]+\frac{m}{2}\left\{{\mathit{SiO}}_2\right\}$$

$$\left(X_n{O}_m\right)+\frac{2m}{3}\left[\mathit{Al}\right]=n\left[X\right]+\frac{m}{3}\left\{{\mathit{Al}}_2{O}_3\right\}$$

"X" generally stands for a metal component such as chromium or manganese.

The above reaction equations (1) and (2) describe a chemical reduction process between slag and metal, which takes place using a vacuum and strong inert gas stirring (usually with argon).

The invention is based on the object of developing a method of the type mentioned at the outset in such a way that it is possible to achieve a reduction in the treatment time of the melt, in order to thereby enable economic advantages. Furthermore, the consumption of the required input materials should be reduced additively or alternatively.

The solution to this problem provided by the invention is characterized in that oxygen is added to the melt before the end of the converter process to form slag, with no reduction of the slag taking place in the converter process, and that reduction only takes place in the subsequent vacuum process the slag takes place.

The converter process and the vacuum process can be carried out in a single metallurgical vessel. The process can also be carried out in a plant tandem converter VOD (VOD process - Vacuum Oxygen Decarburisation).

The pressure during the vacuum process is preferably kept below 100 mbar.

The temperature of the slag when carrying out the vacuum process is preferably kept between 1,720° C. and 1,790° C. in the case of the production of a chromium alloy.

The temperature of the slag when carrying out the vacuum process is preferably kept between 1,600° C. and 1,700° C. in the case of the production of a manganese alloy.

During the converter process, oxygen is preferably blown in until the final carbon content in the melt is at least 95%, preferably 98%, of the oxygen-carbon balance.

A slag former, in particular in the form of fluorspar (CaF ₂ ), aluminum oxide (Al ₂ O ₃ ) and/or sand, can be added to the melt to achieve a high degree of liquefaction of the slag.

In the case of the production of a chromium alloy, the slag that forms in the converter process is preferably kept at a basicity of between 1.2 and 1.5, for which purpose lime is added to the melt.

In the case of the production of a manganese alloy, the slag that forms in the converter process is preferably kept at a basicity of between 1.3 and 1.5, for which purpose lime is added to the melt.

Thus, in the last oxygen blowing period during the converter treatment, due to said final carbon content, a conditioned liquid slag with very high oxygen reactivity and low viscosity is formed. The desired high oxygen reactivity is set in a targeted manner by excess oxygen (overblowing) and the formation of metal oxides, chromium or, in the case of Mn alloys, manganese.

The supply of oxygen is targeted and based on the thermodynamic carbon balance.

The excess oxygen is bound in the slag as an oxide and also dissolved in the liquid metal. The addition of oxygen is determined and adjusted in such a way that targeted reduction with carbon is possible under the subsequent vacuum.

The desired low viscosity of the slag is ensured by a correspondingly high temperature, in particular for metal oxidation, especially of chromium.

The deep decarburization during the vacuum process when reducing the slag with carbon takes place at the high temperature mentioned and with a set oxygen-inert gas ratio.

The converter treatment of the melt (i.e. the first phase of the process) thus ends without slag reduction.

The invention thus provides that the converter reduction is moved to the vacuum step and integrated there (see the below described figures 1 and 2 ).

A deep vacuum and a high temperature of the melt in the vacuum process replace the reduction process in the converter completely and with better quality. The relocation of the converter reduction process and a special conditioning of the slag in the converter process significantly improves the economic efficiency of the process.

• Es erfolgt eine Konverter-Behandlung ohne Schlacke-Reduktion.
• Es wird eine hoher End-Schlacke-Reaktivität sichergestellt.

Compared to the previously known method, as described at the beginning, the solution according to the invention now results in the following:

• There is a converter treatment without slag reduction.
• A high final slag reactivity is ensured.

The final converter oxygen blow period not only aims at a final carbon content, but also at a conditioned slag with very high oxygen reactivity. The oxygen reactivity results from an excess of oxygen (overblowing) and the formation of metal oxides (see the Figures 3 and 4 ).

The slag has a low viscosity. It is set by a high temperature of the metal oxide formation and the use of liquefiers (such as Fluor-Spar (CaF ₂ ), Al ₂ O ₃ or sand).

The treatment temperatures of the slag are high and preferably in the range mentioned.

Before the vacuum treatment, the slagging of the melt is abolished.

The reduction of the converter slag with carbon takes place under a deep vacuum and high temperature.

The preferred high temperature and the preferred deep vacuum with a sufficient degree of oxidation of the slag and the conditions mentioned lead to complete, targeted decarburization. An external oxygen supply (bubbles) in the melt is only necessary if the described Conditions or requirements of the process are not met if, in particular, the degree of oxidation of the slag or the temperature of the melt do not correspond to the thermodynamic conditions.

According to a preferred embodiment, the invention enables carbon refining by conditioned, highly chromium-oxidized converter slag in converter vacuum technology for the production of chromium alloys with a carbon content of less than 0.1%. The converter treatment of the melt takes place by generating a highly reactive, conditioned liquid slag, in particular when the dissolved oxygen content in the melt is more than 50 ppm. The slag conditioning is based on an adjustment of the chromium oxide concentration of more than 20% at a low slag viscosity. The final oxygen blowing period of the converter treatment is aimed with excess O ₂ to a carbon content in the range of less than 0.5% approximately, preferably exactly, the chromium-carbon equilibrium concentration. A highly reactive slag is thus formed. In this case, the slag temperature is preferably between 1720° C. and 1790° C. (without intermediate tapping between 1720° C. and 1770° C.). The basicity of the converter slag is preferably in the range between 1.2 and 1.5. The excess oxygen, bound in the slag as chromium oxide and as dissolved oxygen in the liquid melt, is calculated and adjusted in such a way that targeted reduction decarburization and thus the carbon target value is achieved under vacuum without external oxygen supply. The slag viscosity corresponds to a quasi-aqueous state and is adjusted by a correspondingly high temperature of the chromium oxidation. There is a strong reduction in the amount of slag in the vacuum process due to chrome being returned to the metal. At the end of the vacuum treatment, a small residual slag with FeSi or Al can be left.

Furthermore, according to a preferred embodiment, the invention enables carbon refining through conditioned, highly manganese-oxidized converter slag in converter vacuum technology for the production of manganese alloys with a carbon content of less than 0.1%. Contemplated is a liquid ferromanganese decarburized in an air atmosphere converter to a level of at least 95% carbon balance, typically about 0.5%, and a conditioned high manganese oxidized slag formed in the final decarburization period of the converter -process. The high oxygen content of the slag bound in the form of manganese oxide is a reserve of oxygen for a reducing decarburization period of the subsequent vacuum treatment. The slag reduction takes place with carbon under reduced pressure, strong mixing of the metal and the slag with inert gas or stirring gas at a temperature that is at least 200 K higher than the manganese liquidus temperature of 1,246 °C. The process again runs in a process line consisting of a converter and a vacuum system or a vacuum converter system as a metallurgical unit, which also applies to the other cases mentioned.

The converter treatment of the ferromanganese melt ends with a highly reactive conditioned liquid slag with manganese oxide and a dissolved oxygen content in the melt greater than 100 ppm. The slag conditioning is based on setting manganese oxide concentration higher than 30% and low viscosity. The low slag viscosity corresponds to a quasi-aqueous state and is basically set by the high temperature of the manganese oxidation. The control of the slag temperatures is preferably in the range between 1,600°C and 1,700°C. The basicity of the converter slag is in the range between 1.3 and 1.5. The final oxygen blowing period of the converter treatment aims for a final carbon content in the range of less than 0.5% carbon equal to the equilibrium manganese-carbon concentration away. This forms the extremely highly reactive slag. The targeted oxygen supply for the purpose of manganese oxide formation is based on a thermodynamic carbon reaction potential, expressed by a difference between the current carbon in the melt and its thermodynamic equilibrium concentration. Manganese oxidation is strongly promoted by blowing over the melt to a carbon content equal to the equilibrium concentration. The excess oxygen from the blowing process, bound as manganese oxide in the slag and as dissolved oxygen in the liquid melt, is calculated and adjusted in such a way that targeted reduction decarburization and thus the carbon target value is achieved under vacuum without external oxygen supply . The deep decarburization below 0.1% takes place with the converter slag reduction. It is run with carbon under a vacuum of less than 100 mbar, a temperature in the range between 1,600 °C and 1,700 °C and under the conditions specified above in the downstream vacuum process. Strong inert gas agitation, mostly with argon, takes place during the process. Depending on the type of process control, the reduction time usually lasts between 10 and 15 minutes. The average inert gas consumption, e.g. B. of argon, in the reduction period is 5 to 10 Nm ³ / t FeMn. The vacuum of less than 100 mbar and the high temperature of the melt in the vacuum process lead to the complete reduction process. Due to the high evaporation of manganese, especially under vacuum, the process control is limited to the temperature range mentioned. There is a strong reduction in the amount of slag in the vacuum process due to manganese being returned to the metal. At the end of the vacuum treatment, a small residual slag with FeSi or Al can be left.

For alloys of this type, decarburization takes place in such a way that a conditioned, highly metal-oxidized slag is produced in the final decarburization phase of the converter process (ie in the first phase of the process), whereupon in the vacuum process (ie in the second, subsequent phase of Process) a strong decarburization of the melt takes place. The slag reduction in the second phase proceeds with carbon under greatly reduced pressure and high temperature.

• Die Behandlungszeit (Reduktionszeit) kann verkürzt werden. Sie liegt bevorzugt zwischen 6 und 15 Minuten.
• Der durchschnittliche Inertgas-Verbrauch (beispielsweise von Argon) in der Reduktionsperiode liegt bis 7 Nm³/t Legierung.
• Der FF-Material-Verbrauch (Verbrauch an feuerfestem Material) kann vermindert werden, insbesondere auf unter 6,8 kg/ t Legierung, wodurch sich eine Verlängerung des Konverter-Einsatzes um ca. 10 bis 15 % ergibt.
• Der Energiehaushalt der Schmelze kann verbessert werden.

The following advantages can thus be achieved by the proposed procedure:

• The treatment time (reduction time) can be shortened. It is preferably between 6 and 15 minutes.
• The average consumption of inert gas (e.g. argon) in the reduction period is up to 7 Nm ³ /t alloy.
• The consumption of FF material (consumption of refractory material) can be reduced, in particular to below 6.8 kg/t alloy, which results in an extension of the converter use by approx. 10 to 15%.
• The energy balance of the melt can be improved.

By eliminating skimming before vacuum treatment, the temperature loss of the melt can be reduced in the range of 15 to 23 K.

Savings of reducing agents of approx. 11.0 kg/t alloy Si or 14.5 kg/t alloy Al can be achieved.

Likewise, a saving of slag-forming agents of approx. 45 kg/t Lime alloy and 3 to 5 kg/t Fluorspar alloy can be achieved.

Fig. 1

zeigt schematisch ein erfindungsgemäßes Konverter-Vakuum-Verfahren mit Zwischen-Abstich,

Fig. 2

zeigt schematisch ein erfindungsgemäßes Konverter-Vakuum-Verfahren ohne Zwischen-Abstich,

Fig. 3

zeigt schematisch das Prinzip der Entkohlung bei der Reduzierung einer Schlacke mit Kohlenstoff in einer Linie aus Konverter- und VOD-Anlage (Vakuum Oxygen Decarburisation),

Fig. 4

zeigt schematisch das Prinzip der Entkohlung bei der Reduzierung einer Schlacke mit Kohlenstoff in einem Vakuum-Konverter,

Fig. 5

zeigt schematisch das Kohlenstoff-Gleichgewicht für FeCr (d. h. thermodynamischen Gleichgewichte zwischen Kohlenstoff und Chrom) bei unterschiedlichen Prozessbedingungen und

Fig. 6

zeigt schematisch das Kohlenstoff-Gleichgewicht für FeMn (d. h. thermodynamischen Gleichgewichte zwischen Kohlenstoff und Mangan) bei unterschiedlichen Prozessbedingungen.

Exemplary embodiments of the invention are shown in the drawing.

1

shows schematically a converter vacuum process according to the invention with intermediate tapping,

2

shows schematically a converter vacuum process according to the invention without intermediate tapping,

3

shows schematically the principle of decarburization when reducing a slag with carbon in a line consisting of converter and VOD plant (vacuum oxygen decarburization),

4

shows schematically the principle of decarburization when reducing a slag with carbon in a vacuum converter,

figure 5

shows schematically the carbon balance for FeCr (ie thermodynamic equilibria between carbon and chromium) at different process conditions and

6

shows schematically the carbon balance for FeMn (ie thermodynamic equilibria between carbon and manganese) at different process conditions.

In the Figures 1 to 4 shows the various sub-processes that result from the combined converter-vacuum process (with and without tapping), where (according to figure 3 ) the converter process can be separated from the vacuum process or (according to figure 4 ) a combination of the two sub-processes takes place.

wobei bedeutet:

(-dC/dt)

Entkohlungsgeschwindigkeit

C

aktueller Kohlenstoffgehalt

C*

Kohlenstoffgleichgewicht

τ

Entkohlungszeitkonstante

Low carbon contents are achievable in the metal-slag system with the presence of oxygen and at greatly reduced process pressure. The vacuum causes a reduction in the carbon balance. The difference between The temporary carbon content and the carbon balance, naturally understood as reaction potential, form the driving force of the oxygen-carbon reaction. The greater the reaction potential, the greater the decarburization rate according to equation (3) below: $$\left(-\frac{\mathit{DC}}{\mathit{German}}\right)=\frac{1}{\tau }\left(C-C*\right)$$

where means:

(-dC/dt)

decarburization rate

C

current carbon content

C*

carbon balance

τ

decarburization time constant

wird das thermodynamische Gleichgewicht der X_nO_m -Reduktion durch Kohlenstoff wie folgt gemäß Gleichung (5) beschrieben: $$K_{C,X}\left(T\right)=\frac{a_X^n{p}_{\mathit{CO}}^m}{a_{X_n{O}_m}{a}_C^m}$$

With the illustrated sequence of chemical reactions in the liquid metal according to Equation (4) $$\begin{array}{l}\left\{O_2\right\}=2\left[O\right]\\ n\left[X\right]+m\left[O\right]=\left(X_n{O}_m\right)\\ \left(X_n{O}_m\right)+m\left[C\right]=n\left[X\right]+m\left\{\mathit{CO}\right\}\end{array}$$

the thermodynamic equilibrium of X _n O _m reduction by carbon is described as follows according to equation (5): $$K_{C,X}\left(T\right)=\frac{a_X^n{p}_{\mathit{CO}}^m}{a_{X_n{O}_m}{a}_C^m}$$

wobei $$\begin{array}{l}{a}_C={ƒ}_{C}C*\\ a_X={ƒ}_{X}X\\ p_{\mathit{CO}}=\frac{R}{R+\mathrm{0,5}}p\end{array}$$

X

Metall-Komponente wie Chrom, Mangan und Eisen

ac

Kohlenstoffaktivität

fc

Kohlenstoff-Aktivitätskoeffizient

ax

Element X-Aktivität

fx

Element X-Aktivitätskoeffizient

R

O₂/ Inertgas-Verhältnis

aXnOm

Schlacken-Komponente XnOm-Aktivität

p, pCO

Prozessdruck, Kohlenmonoxid-Partialdruck

KC,X(T)

Kohlenstoff-Element X - Reaktionskonstante in Funktion der Temperatur

$$C*=\frac{{\left({ƒ}_{X}X\right)}^{\frac{n}{m}}}{{ƒ}_C{a}_{X_n{O}_m}^{\frac{1}{m}}{K}_{C,X}{\left(T\right)}^{\frac{1}{m}}}\frac{R}{R+\mathrm{0,5}}p$$

After solving Equation (5) and using Equation (6) below, Equation (7) can be obtained as given below, from which the dependency of the carbon balance on the external process pressure according to Equation (8) can be seen: $$a_C=\frac{a_X^{\frac{n}{m}}{p}_{\mathit{CO}}}{a_{X_n{O}_m}^{\frac{1}{m}}{K}_{C,X}{\left(T\right)}^{\frac{1}{m}}}$$

whereby $$\begin{array}{l}{a}_C={ƒ}_{C}C*\\ a_X={ƒ}_{X}X\\ p_{\mathit{CO}}=\frac{R}{R+0.5}p\end{array}$$

X

Metal component such as chromium, manganese and iron

ac

carbon activity

FC

carbon activity coefficient

ax

Element X activity

fx

Element X activity coefficient

R

O ₂ / inert gas ratio

aXnOm

Slag component XnOm activity

p, pCO

Process pressure, carbon monoxide partial pressure

KC,X(T)

Carbon element X - reaction constant as a function of temperature

$$C*=\frac{{\left({ƒ}_{X}X\right)}^{\frac{n}{m}}}{{ƒ}_C{a}_{X_n{O}_m}^{\frac{1}{m}}{K}_{C,X}{\left(T\right)}^{\frac{1}{m}}}\frac{R}{R+0.5}p$$

Out of figure 5 it can be seen that the carbon-chromium reaction equilibrium occurs at a pressure of 1.0 bar, a temperature of 1,750 °C, a chromium content of 78% and the ratio R of 0.03 at 0.4%. The result states that further oxygen supply after equilibrium has been reached forces strong oxidation of chromium and promotes the reactivity of the melt. In the further vacuum process at a pressure of 0.1 bar and at an R ratio of 0.02, there is a strong shift in equilibrium to the level of 0.04%. This value limits the decarburization. It is only possible if the equilibrium is lowered by vacuum, temperature or blowing ratio.

Out of figure 6 it can be seen that the carbon-manganese reaction equilibrium is set at 0.62% at a pressure of 1.0 bar, a temperature of 1,600 °C, a manganese content of 75% and the ratio R of 0.05. The result states that further oxygen supply after equilibrium has been reached forces strong oxidation of manganese and promotes the reactivity of the slag. In the further vacuum process at a pressure of 0.1 bar and with the same R ratio of 0.05, the equilibrium shifts sharply to the level of 0.04%. This value limits the decarburization. It is only possible if the equilibrium is lowered by vacuum, temperature or blowing ratio of O ₂ /inert gas.

How out figure 5 and 6 with the depiction of the equilibria, both the process management through the vacuum and the temperature control as well as the controlled blowing of oxygen and inert gas or stirring gas (ie the O ₂ /inert gas ratio) are very flexible. The relevant parameters have a significant impact on the efficiency of decarburization. Depending on the alloy type being produced, different variations between the temperature-pressure ratio and the O ₂ /inert gas ratio can be selected within the framework of the preconditions. The temperature is set in Converter process and the pressure in the vacuum process, setting the ratio applies to both sub-processes. It should be noted that the endothermic course of the slag reduction must be taken into account in the energy balance of the process. It causes the metal temperature to decrease.

A process control calculates, optimizes and implements the relevant parameters and the conditions of the process. The determination of the decarburization between the end of the converter process and the target analysis after the vacuum step is decisive in order to achieve the carbon target analysis. This value further determines the necessary oxygen demand for metal oxidation. Corrections to the amount of oxygen are not excluded and may result from further need for temperature adjustment and slag former additions related to basicity.

Claims (10)

Method for producing a ferroalloy with a low carbon content, in particular a chromium alloy or a manganese alloy with a carbon content of less than 0.1%, in which a melt of the ferroalloy is first treated in a converter process by adding oxygen and then in a subsequent vacuum process the melt prepared in this way is decarburized,
characterized,
that oxygen is added to the melt before the end of the converter process to form slag, with no reduction of the slag taking place in the converter process, and that the slag is only reduced in the subsequent vacuum process. Method according to Claim 1, characterized in that the converter process and the vacuum process are carried out in a single metallurgical vessel. Method according to Claim 1, characterized in that the converter process and the vacuum process are carried out in a plant tandem converter VOD (vacuum oxygen decarburization process). Method according to one of Claims 1 to 3, characterized in that the pressure during the vacuum process is kept below 100 mbar. Method according to one of Claims 1 to 4, characterized in that the temperature of the slag is kept between 1,720 °C and 1,790 °C during the implementation of the vacuum process in the case of the production of a chromium alloy. Method according to one of Claims 1 to 4, characterized in that the temperature of the slag is kept between 1,600°C and 1,700°C during the implementation of the vacuum process in the case of the production of a manganese alloy. Method according to one of Claims 1 to 6, characterized in that oxygen is blown in during the converter process until the final carbon content in the melt is at least 95%, preferably at least 98%, of the oxygen-carbon balance present. The method according to any one of claims 1 to 7, characterized in that the melt to achieve a high degree of liquefaction of Slag a slag former, in particular in the form of fluorspar (CaF ₂ ), aluminum oxide (Al ₂ O ₃ ) and / or sand, is added. Method according to one of Claims 1 to 8, characterized in that the slag forming in the converter process is kept at a basicity of between 1.2 and 1.5 in the case of the production of a chromium alloy, for which purpose lime is added to the melt. Method according to one of Claims 1 to 8, characterized in that the slag forming in the converter process is kept at a basicity of between 1.3 and 1.5 in the case of the production of a manganese alloy, for which purpose lime is added to the melt.

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