Treatment of transient phenomena in analysis of slag-metal-gas reaction kinetics

Equations commonly used in describing reaction kinetics are examined and the problem of applying such equations to transient processes is discussed. Three examples of transient phenomena are examined in detail. It is shown that for carbon injection into slag, the reaction can be described by employing data for carbon oxidation in CO/CO2 by assuming reaction conditions approximately halfway between those in equilibrium with the slag and those in equilibrium with carbon. It is demonstrated that, when the time averaged interfacial area is employed, the rate of reaction between slag and iron-aluminum alloys can be described by a single first order rate equation, accommodating a 300% change in interfacial area. Creation of surface area in oxygen steelmaking is discussed and a method to determine the size distribution of droplets that are generated is proposed. It is concluded that changes in conditions during reaction complicate the analysis of kinetics. However, it should be possible to develop quantitative kinetic models to describe real processes

Dynamic model of basic oxygen steelmaking process based on multi-zone reaction kinetics : modelling of manganese removal

In the earlier work, a dynamic model for the BOF process based on the multi-zone reaction kinetics has been developed. In the preceding part, the mechanism of manganese transfer in three reactive zones of the converter has been analyzed. This study identifies that temperature at the slag-metal reaction interface plays a major role in the Mn reaction kinetics and thus a mathematical treatment to evaluate temperature at each reaction interface has been successfully employed in the rate calculation. The Mn removal rate obtained from different zones of the converter predicts that the first stage of the blow is dominated by the oxidation of Mn at the jet impact zone, albeit some additional Mn refining has been observed as a result of the oxidation of metal droplets in emulsion phase. The mathematical model predicts that the reversion of Mn from slag to metal primarily takes place at the metal droplet in the emulsion due to an excessive increase in slag-metal interface temperature during the middle stage of blowing. In the final stage of the blow, the competition between simultaneous reactions in jet impact and emulsion zone controls the direction of mass flow of manganese. Further, the model prediction shows that the Mn refining in the emulsion is a strong function of droplet diameter and the residence time. Smaller sized droplets approach equilibrium quickly and thus contribute to a significant Mn conversion between slag and metal compared to the larger sized ones. The overall model prediction for Mn in the hot metal has been found to be in good agreement with two sets of different size top blowing converter data reported in the literature

Dynamic model of basic oxygen steelmaking process based on multi-zone reaction kinetics : model derivation and validation

A multi-zone kinetic model coupled with a dynamic slag generation model was developed for the simulation of hot metal and slag composition during the BOF operation. The three reaction zones, (i) jet impact zone (ii) slag-bulk metal zone (iii) slag-metal-gas emulsion zone were considered for the calculation of overall refining kinetics. In the rate equations, the transient rate parameters were mathematically described as a function of process variables. A micro and macroscopic rate calculation methodology (micro-kinetics and macro-kinetics) were developed to estimate the total refining contributed by the recirculating metal droplets through the slag-metal emulsion zone. The micro-kinetics involves developing the rate equation for individual droplets in the emulsion. The mathematical models for the size distribution of initial droplets, kinetics of simultaneous refining of elements, the residence time in the emulsion, dynamic interfacial area change were established in the micro-kinetic model. In the macro-kinetics calculation, a droplet generation model was employed and the total amount of refining by emulsion was calculated by summing the refining from the entire population of returning droplets. A dynamic FetO generation model based on oxygen mass balance was developed and coupled with the multi-zone kinetic model. The effect of post combustion on the evolution of slag and metal composition was investigated. The model was applied to a 200-ton top blowing converter and the simulated value of metal and slag was found to be in good agreement with the measured data. The post-combustion ratio was found to be an important factor in controlling FetO content in the slag and the kinetics of Mn and P in a BOF process

Investigation into the cause of spontaneous emulsification of a free steel droplet : validation of the chemical exchange pathway

Small Fe-based droplets have been heated to a molten phase suspended within a slag medium to replicate a partial environment within the basic oxygen furnace (BOF). The confocal scanning laser microscope (CSLM) has been used as a heating platform to interrogate the effect of impurities and their transfer across the metal/slag interface, on the emulsification of the droplet into the slag medium. The samples were then examined through X-ray computer tomography (XCT) giving the mapping of emulsion dispersion in 3D space, calculating the changing of interfacial area between the two materials, and changes of material volume due to material transfer between metal and slag. Null experiments to rule out thermal gradients being the cause of emulsification have been conducted as well as replication of the previously reported study by Assis et al.[1] which has given insights into the mechanism of emulsification. Finally chemical analysis was conducted to discover the transfer of oxygen to be the cause of emulsification, leading to a new study of a system with undergoing oxygen equilibration

Failure analysis of air cooled condenser gearbox

Gears are very reliable components and normally work 5–6 years without failure. This article is a case study of failure analysis of a gearbox which was failed in three months after its installation. The problem was identified by maintenance engineers through vibration monitoring of gearbox. Hardness measurement of case and core revealed that the core was harder than case and the applied load was sufficiently high for failure of gear. Recommendations were given to improve the fatigue life of gearbox