Validated kinetic modelling of ladle furnace process for predicting inclusions in API steel grade

A kinetic model of ladle furnace (LF) process is developed in C++ format using the FactSage database and ChemApp subroutines. The model considers all the process parameters such as ferroalloy and slag dissolution, wire additions, electrical arcing, steel/slag reactions, reoxidation due to slag eye opening, heat exchange between metal/slag, and refractory dissolution. Further, a correlation for inclusion removal rate was developed as a function of argon flow rate, using discrete phase method (DPM) in Computational Fluid dynamics (CFD). Lollypop samples from steel bath and slag samples were collected from the plant for API steel grade for chemical analysis and inclusion characterisation. At LF_in, the inclusions found were mostly alumina spinel with very low amount of Mg (∼3%), followed by spinel at intermediate stage having ∼15 wt. % of Mg and after Ca treatment, inclusions transformed into CaS and Calcium Aluminate type of inclusions. Overall inclusion weight fraction varied from 136 ppm at LF_in to 93 ppm at LF_out. The model calculations were found to give very good prediction for steel and slag chemistry, and inclusion global composition as compared to the plant results. Predicted temperature was found with an accuracy of ± 5 o C, while the calculated inclusion weight fraction was having an accuracy of ±12 ppm.