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Study of Steel from Sponge Iron – At a Glance - Coggle Diagram
Study of Steel from Sponge Iron – At a Glance
Background & Problem
Steel Production Routes in India
:
Primary Route
: Blast Furnace → Basic Oxygen Furnace (BOF)
Secondary Route
: Sponge Iron (DRI) + Scrap → Induction Furnace (IF
Issue
: High phosphorus (P) content (up to 0.096%) in DRI-based steel.
Govt. Regulation
: Steel must have < 0.085% combined (S+P).
Method and Experiment
Furnace Setup
Neutral (Magnesia-based) lining (replaces acidic lining).
Double slagging technique applied.
Slag Additives Tested
:
Barium Aluminate (Best result)
Calcium Aluminate
Calcium Barium Aluminate
Key Factors for P Removal:
FeO in DRI (provides oxidation potential)
Low temperature (prevents P reversion).
High slag basicity (captures P as P₂O₅).
Objective
Dephosphorization of steel in 150 kg Induction Furnace (IF).
Compare effectiveness of synthetic slags (Barium Aluminate, Calcium Aluminate, etc.).
Advantages of Induction Furnace (over EAF)
Lower power consumption.
Faster melting.
Less chromium oxidation.
No electrodes → Lower carbon contamination.
Results
Dephosphorization Efficiency
:
21.74% to 55.55% (highest with Barium Aluminate)
Optimal Slag Conditions:
FeO = 15–35%
Low SiO₂ & Al₂O₃
Manual slag churning
(improves reaction).
Challenges in IF Steelmaking
Acidic lining → Hinders P/S removal.
Shallow bath depth → Difficult oxygen lancing.
Slag temperature control (upper slag cools in air).
Conclusions & Recommendations
Best Method
: Barium Aluminate + Double Slagging + Basic Lining.
Critical Controls:
Temperature monitoring
Slag basicity & FeO content
Future Work
: More trials needed for optimization.