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Basic Oxygen Steelmaking Process Explained

Basic oxygen steelmaking (BOS) involves blowing oxygen through molten pig iron to lower the carbon content and produce steel. Key aspects include: 1) Molten pig iron and steel scrap are charged into a basic oxygen furnace and oxygen is blown through to burn carbon to carbon monoxide and lower carbon levels. 2) Fluxes are added to absorb impurities into the slag. 3) The process converts pig iron into steel in less than 40 minutes, much faster than older open hearth furnaces. 4) BOS now produces over 60% of the world's steel and greatly improved productivity over previous processes.

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Rahul Pandey
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4K views11 pages

Basic Oxygen Steelmaking Process Explained

Basic oxygen steelmaking (BOS) involves blowing oxygen through molten pig iron to lower the carbon content and produce steel. Key aspects include: 1) Molten pig iron and steel scrap are charged into a basic oxygen furnace and oxygen is blown through to burn carbon to carbon monoxide and lower carbon levels. 2) Fluxes are added to absorb impurities into the slag. 3) The process converts pig iron into steel in less than 40 minutes, much faster than older open hearth furnaces. 4) BOS now produces over 60% of the world's steel and greatly improved productivity over previous processes.

Uploaded by

Rahul Pandey
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
  • Basic Oxygen Steelmaking
  • BOS Converter Inputs
  • Tapping and Slag Handling
  • Refractory Usage
  • Nitrogen Slashing
  • Process Model Development
  • Metal Degassing
  • Additional Processes

Basic oxygen steelmaking (BOS, BOP, BOF, and OSM), also known as Linz-Donawitz-Verfahren [1] steelmaking or the oxygen

converter process is a method of primary steelmaking in which carbonrich molten pig iron is made into steel. Blowing oxygen through molten pig iron lowers the carbon content of the alloy and changes it into low-carbon steel. The process is known as basic due to the type of refractoriescalcium oxide and magnesium oxidethat line the vessel to withstand the high temperature of molten metal. The process was developed in 1948 by Robert Durrer and commercialized in 19521953 by Austrian VOEST and AMG. The LD converter, named after the Austrian towns Linz and Donawitz (a district of Leoben) is a refined version of the Bessemer converter where blowing of air is replaced with blowing oxygen. It reduced capital cost of the plants, time of smelting, and increased labor productivity. Between 1920 and 2000, labor requirements in the industry decreased by a factor of 1,000, from more [2] than 3 worker-hours per tonne to just 0.003. The vast majority of steel manufactured in the world is [2] produced using the basic oxygen furnace; in 2000, it accounted for 60% of global steel output. Modern furnaces will take a charge of iron of up to 350 tons and convert it into steel in less than 40 minutes, compared to 1012 hours in an open hearth furnace.

Process

Cross-section of a basic oxygen furnace

The basic oxygen steel-making process is as follows: 1. Molten pig iron (sometimes referred to as "hot metal") from a blast furnace is poured into a large refractory-lined container called a ladle; 2. The metal in the ladle is sent directly for basic oxygen steelmaking or to a pretreatment stage. Pretreatment of the blast furnace metal is used to reduce the refining load of sulfur, silicon, and phosphorus. In desulfurising pretreatment, a lance is lowered into the molten iron in the ladle and several hundred kilograms of powdered magnesium are added. Sulfur impurities are reduced to magnesium sulfide in a violent exothermicreaction. The sulfide is then raked off. Similar pretreatment is possible for desiliconisation and dephosphorisation using mill scale (iron oxide)

and lime as reagents. The decision to pretreat depends on the quality of the blast furnace metal and the required final quality of the BOS steel. 3. Filling the furnace with the ingredients is called charging. The BOS process is autogenous: the required thermal energy is produced during the process. Maintaining the proper charge balance, the ratio of hotmetal to scrap, is therefore very important. The BOS vessel is one-fifth filled with steel scrap. Molten iron from the ladle is added as required by the charge balance. A typical chemistry of hotmetal charged into the BOS vessel is: 4% C, 0.20.8% Si, 0.08%0.18% P, and 0.010.04% S. 4. The vessel is then set upright and a water-cooled lance is lowered down into it. The lance blows 99% pure oxygen onto the steel and iron, igniting the carbon dissolved in the steel and burning it to form carbon monoxide and carbon dioxide, causing the temperature to rise to about 1700C. This melts the scrap, lowers the carbon content of the molten iron and helps remove unwanted chemical elements. It is this use of oxygen instead of air that improves upon the Bessemer process, for the nitrogen (and other gases) in air do not react with the charge as oxygen does. High purity oxygen is blown into the furnace or BOS vessel through a vertically [8] oriented water-cooled lance with velocities faster than Mach 1. 5. Fluxes (burnt lime or dolomite) are fed into the vessel to form slag, which absorbs impurities of the steelmaking process. During blowing the metal in the vessel forms an emulsion with the slag, facilitating the refining process. Near the end of the blowing cycle, which takes about 20 minutes, the temperature is measured and samples are taken. The samples are tested and a computer analysis of the steel given within six minutes. A typical chemistry of the blown metal is 0.3 0.6% C, 0.050.1% Mn, 0.010.03% Si, 0.010.03% S and P. 6. The BOS vessel is tilted again and the steel is poured into a giant ladle. This process is called tapping the steel. The steel is further refined in the ladle furnace, by adding alloying materials to give the steel special properties required by the customer. Sometimes argon or nitrogen gas is bubbled into the ladle to make sure the alloys mix correctly. The steel now contains 0.11% carbon. The more carbon in the steel, the harder it is, but it is also more brittle and less flexible. 7. After the steel is removed from the BOS vessel, the slag, filled with impurities, is poured off and cooled.

8.

GEN FURNACE
LD CONVERTER

(BOF)-

9.

10. Basic Oxygen Furnace is commonly known as BOF process or LD process. Ascompared to open / twin hearth process is fast, energy efficient and simple. Tap to taptime in BOF is around 45-50 minutes. The name BOF Stands B mean basic because basicrefractory is used, O means oxygen as it is blown in converter and F means furnace. 11. Inputs: 12. The major input materials in BOF or LD converter are: 13. 14. 15. Metallic: 16. Hot metal containing around 4% carbon is the main input in theBOF. Scrap is also used as a coolant and is also used in the process. 17. 18. 48 19. 20. 21. Fluxes: 22. Fluxes such as lime, dolomite, iron ore etc. 23. 24. 25. Oxygen: 26. one of the important inputs comes mainly from captive Oxygen plants in addition to the Purchased

liquid oxygen. Oxygen Purity should bemore than 99.0%. 27. 28. 29. Nitrogen: 30. Nitrogen is used for purging and ceiling purpose. It is also usedfor slag splashing. 31. 32. 33. Ferro-Alloys: 34. while tapping the steel Ferro-alloy such as ferro silicon (Fe-Si), silico manganese (Si-Mn), ferro manganese (Fe-Mn) etc are beingadded to make the desired grade of steel. 35. Process: 36. 37. 38. Charging: 39. The process start with mixer in steel melting shop. Metal isstored in Mixers and it is taken out as and when needed. It is charged intoconverter with the help of EOT cranes. In addition to metal, scrap is alsocharged. Charging sequence followed in BOF is first scrap and then metal. 40. 41. 42. Converter blowing: 43. The process of blowing

44. 45. means reaction of Oxygenwith hot metal and fluxes in LD converter. After charging converter is keptvertical and lance is lowered in the converter through which oxygen is blown at a pressure of around 14 kg/cm2. During the blowing process fluxessuch lime, dolomite, iron ore etc are added to make slag. The slag is basic innature. Main impurities carbon reacts with oxygen and is removed in thegaseous form. Impurities like Si, P, S and other non metallic impurities areremoved in the form of slag. The blowing process usually takes 17 [Link] the blowing is complete converter is tilted to take out the slag in aslag pot. Sample and temperature is also taken manually. When desiredcomposition and temperature is achieved the steel is tapped 46. 47. 48 48. 49. 50. Fluxes: 51. Fluxes such as lime, dolomite, iron ore etc. 52. 53. 54. Oxygen: 55. one of the important inputs comes mainly from captive Oxygen plants in addition to the Purchased

liquid oxygen. Oxygen Purity should bemore than 99.0%. 56. 57. 58. Nitrogen: 59. Nitrogen is used for purging and ceiling purpose. It is also usedfor slag splashing. 60. 61. 62. Ferro-Alloys: 63. while tapping the steel Ferro-alloy such as ferro silicon (Fe-Si), silico manganese (Si-Mn), ferro manganese (Fe-Mn) etc are beingadded to make the desired grade of steel. 64. Process: 65. 66. 67. Charging: 68. The process start with mixer in steel melting shop. Metal isstored in Mixers and it is taken out as and when needed. It is charged intoconverter with the help of EOT cranes. In addition to metal, scrap is alsocharged. Charging sequence followed in BOF is first scrap and then metal. 69. 70. 71. Converter blowing: 72. The process of blowing

73. 74. means reaction of Oxygenwith hot metal and fluxes in LD converter. After charging converter is keptvertical and lance is lowered in the converter through which oxygen is blown at a pressure of around 14 kg/cm2. During the blowing process fluxessuch lime, dolomite, iron ore etc are added to make slag. The slag is basic innature. Main impurities carbon reacts with oxygen and is removed in thegaseous form. Impurities like Si, P, S and other non metallic impurities areremoved in the form of slag. The blowing process usually takes 17 [Link] the blowing is complete converter is tilted to take out the slag in aslag pot. Sample and temperature is also taken manually. When desiredcomposition and temperature is achieved the steel is tapped. 75. 76. 77. Tapping 78. : tapping means discharging the liquid steel into ladle through thetap hole present in the converter by tilting it. As per the grade of steel theFerro-alloys are also added into ladle during tapping. As soon as the steelfinishes the converter is lifted and tapping is complete. 79. 80.

81. Nitrogen Slashing 82. : After tapping, the residual slag in the converter issplashed with the help of nitrogen. Converter is kept vertical and lance islowered. Through the same lance nitrogen is blown which splashes the basicresidual slag in the converter and gives a coating on the refractory [Link] advantage of nitrogen splashing is to increase the lining life of theconverter. 83. Refractories : Refractory plays a very important role in
As liquid metal ishandled in BOF so all vessels like mixer, converter, ladle1 BOF shop.

Introduction

In the LD converter process, pure oxygen is blown on a molten iron bath for refining purposes. Elements dissolved in the molten iron, e.g. C, Si, Mn, P, etc., but also part of the molten iron, are oxidised. They either form a slag phase covering the hot metal or, in the case of C, gas bubbles containing CO and CO 2. Several reaction zones can be identified in Figure 1. In the hot spot, the oxygen directly reacts with iron and dissolved elements. Due to the impact of the oxygen jet, iron droplets are dispersed in the slag phase as well as slag droplets in the metal bath. The metal-slag dispersion is mixed further by CO and CO 2 bubbles and serves as the main reaction zone. A third zone contains the hot metal that is not dispersed in the slag, but forms the bath underneath. Droplets from the dispersion fall back into this bath.

Figure 1: LD converter process

2 Process Model Development

The task of developing a suitable converter model will be discussed based on the decarburisation reaction of the iron melt. Obviously, the rate of the decarburisation reaction depends on the reaction rate of

and the transport conditions in the converter. Thereby, these are determined by oxygen blowing conditions and CO formation. On the other hand, CO formation is influenced by the decarburisation reactions. Intermediary formation of FeO in the hot...

84. s etc are lined with refractory bricks. It protects the shell of vessel and retains the metal temperature. Different types of refractory as per their usage are given below: 85. 86. 87. Converter Vessel: 88. The bricks used here are basic in nature. Dolomite bricksor magnesia carbon bricks are commonly used in converter. In recent timesmagnesia carbon bricks have replaced dolomite bricks. Number of heatsmade in a converter from one new lining to next lining is known as thelining life of the converter. Now a days all plants are trying to achievehigher lining lif

89.

1 Introduction

90. In the LD converter process, pure oxygen is blown on a molten iron bath for refining purposes. Elements dissolved in the molten iron, e.g. C, Si, Mn, P, etc., but also part of the molten iron, are oxidised. They either form a slag phase covering the hot metal or, in the case of C, gas bubbles containing CO and CO2. Several reaction zones can be identified in Figure 1. In the hot spot, the oxygen directly reacts with iron and dissolved elements. Due to the impact of the oxygen jet, iron droplets are dispersed in the slag phase as well as slag droplets in the metal bath. The metal-slag dispersion is mixed further by CO and CO 2 bubbles and serves as the main reaction zone. A third zone contains the hot metal that is not dispersed in the slag, but forms the bath underneath. Droplets from the dispersion fall back into this bath.

91. Figure 1: LD converter process

92.

2 Process Model Development

93. The task of developing a suitable converter model will be discussed based on the decarburisation reaction of the iron melt. Obviously, the rate of the decarburisation reaction depends on the reaction rate of 94. 95. and the transport conditions in the converter. Thereby, these are determined by oxygen blowing conditions and CO formation. On the other hand, CO formation is influenced by the decarburisation reactions. 96. Intermediary formation of FeO in the hot...
iquid Argon Purity level (ArcelorMittal Tubaro standard): contamination = 5ppm of N2 and = 3 ppm of O2. Characteristics: odourless, non-reactive, inert. Common uses:

Steel works: Metal degassing - after leaving the converters the steel goes through a degassing process where hydrogen and other impurities are removed during a fusion process; Electric welding; Thermo-chemical treatment; Inertization; Atomic Absorption; Optical Fibres; Chemical Processes.

Liquid Oxygen Purity level (ArcelorMittal Tubaro standard): 99.40%. Characteristics: colourless, highly oxidant. This oxidant characteristic defines it as a dangerous gas requiring special handling procedure.

Common uses:

Steel works: LD Converter - liquid oxygen is used for oxidation in this type of converter to allow temperature increase, increasing hot metal viscosity and bubbling to ensure the necessary chemical reactions to separate impurities, produce slag and the final product steel. Optical Fibres; Laser; Medicine.

Liquid Nitrogen Purity level (ArcelorMittal Tubaro standard): contamination = 100 ppm of O2. Characteristics: colourless, odourless, relatively non-reactive, asphyxiating. Common uses:

Steel works: Metal degassing; Coke dry quenching (CDQ) - inert gas used in coke dry quenching at ArcelorMittal TubaroCoke Plant (only company in Brazil using the CDQ process); Thermo-chemical treatment; Atomic Absorption; Equipment for orthopaedic and brain surgeries; Laser; Chemical Processes.

Common questions

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The 'tapping' step is critical as it involves discharging the molten steel into a ladle while ensuring that the desired chemical composition and temperature are achieved. It also includes the addition of ferro-alloys to define the grade and properties of the final steel product. Proper tapping ensures the homogenization of the steel, impacting its quality and performance in various applications . The precision in tapping contributes to achieving the specified mechanical properties in the steel .

High purity oxygen, often greater than 99%, is crucial in the basic oxygen steelmaking process because it directly impacts the efficiency of decarburization and the removal of impurities. Using oxygen instead of air decreases the presence of nitrogen and other gases which do not react with the charge, leading to a more efficient reaction process . Moreover, pure oxygen allows for higher temperatures, which are necessary for melting scrap and reducing unwanted chemical elements .

Basic oxygen steelmaking significantly improved industrial productivity by drastically reducing the smelting time from 10-12 hours required in an open hearth furnace to just under 40 minutes. It also minimized capital costs and increased labor productivity by reducing the labor hours needed per tonne of steel from over 3 to as low as 0.003 hours . These improvements mean that the process can handle larger volumes at faster rates, leading to higher outputs and reduced costs .

Fluxes such as lime and dolomite are used in the steelmaking process to form slag, which absorbs impurities like sulfur, phosphorous, and silicon. The removal of these elements is crucial as they can cause brittleness in steel. The slag that forms is basic in nature and helps facilitate the refining process by creating a metal-slag emulsion, which is vital for trapping impurities away from the molten metal .

The use of basic refractories like dolomite and magnesia carbon bricks in BOF vessels provides insulating properties that help retain high temperatures necessary for the steelmaking process. This contributes to process sustainability by extending the life of the furnace linings and by reducing energy losses, thus economizing the overall process. Additionally, it minimizes the need for frequent maintenance and replacement, reducing resource consumption and environmental impact .

The composition of hot metal entering the BOF, specifically its carbon, silicon, phosphorus, and sulfur content, greatly influences the refinement process. Higher levels of impurities can increase the burden on pretreatment and slag formation stages, while optimal compositions contribute to smoother decarburization and impurity reduction, affecting the quality of the steel produced. The initial composition dictates the amount and type of fluxes needed, potentially impacting cost and furnace operations .

Carbon is a key determinant of steel's hardness and strength but also increases brittleness. In the steelmaking process, reducing carbon content is essential for producing steel with varied mechanical properties, suited for different applications. The process requires careful balancing; while higher carbon content increases hardness, it requires removal or adjustment to achieve desired malleability and toughness. Excess carbon is burnt off during the oxygen blowing phase, influencing slag formation and energy balance in the process .

Nitrogen, though not a reactive part of the steelmaking in the BOF, serves important roles such as purging and lance cooling. After the steel tapping, nitrogen is used for slashing, where it helps in splashing the remaining slag to coat the refractory lining. This process extends the life of the converter's lining by reducing structural wear through thermal protection. This strategic use of nitrogen also aids in controlling the atmosphere within the vessel to prevent oxidation during steel treatment .

The BOF process, by replacing air with pure oxygen and using a more controlled approach to oxidation and energy utilization, results in fewer greenhouse gas emissions and improved energy efficiency compared to ancient methods like the Bessemer and open hearth processes. The decreased use of energy, along with efficient removal of impurities and production of high-quality slag, means less environmental contamination and hazardous by-products, harnessing resources more sustainably .

The basic oxygen steelmaking (BOS) process is termed 'autogenous' because the necessary thermal energy is internally generated by the exothermal reactions between the oxygen and the molten metal, especially carbon combustion to CO and CO2. This characteristic eliminates the need for external energy sources, reducing energy costs and contributing to the process efficiency. The autogenous nature means that, once initiated, the process sustains itself, thus enhancing the overall energy efficiency of steel production .

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