4 Aod
4 Aod
4 Aod
Contents:
Introduction
AOD process
Introduction
Stainless steels contain typically 10-30 % chromium besides other elements like C, Mn, Si, S etc.
Chromium imparts corrosion resistance to steel. Varying amounts of other alloying elements like Ni, Mo,
V, Ti, Ni, etc may be added to obtain certain specific property. There are different types of stainless
steels like
Austenitic stainless steels: which contain 18% Cr, 8% Ni, and C is in between 0.03-0.15%
Ferritic stainless steels: which contain 12% to 30% Cr and 0.08% to 0.12%C.
Martensitic stainless steels: which contain around 13% Cr and C varying in between 0.15% to 0.25%.
Certain grades contain C 0.6% to 0.95%.
Precipitation hardenable stainless steel: contain 18-20% Cr, 8 to 10 % Ni and copper, Titanium,
Aluminum.
It may be noted that all stainless steels contain chromium and carbon besides other elements.
Production of stainless steels requires controlling chromium and carbon.
In stainless steel making both chromium and carbon oxidizes when decarburization of melt is done. The
Ellingham diagram for oxide formation indicates that carbon oxidation in preference to chromium
oxidation can occur at temperatures greater than 1220oC, when both elements are in pure state. Under
all practical conditions carbon oxidation can occur at temperatures above 1800oC in presence of
chromium.
Chromium oxidizes to Cr2 O3 or Cr3 O4 and C oxidizes to CO.
2C + O2 = 2CO
Assuming pure Cr3 O4 and Cr and using henry’s law for carbon, it follows
[f cr w cr ]3 p 4co
𝐾𝐾 = [f C w c ]4
2)
[W cr ]3 K×(f c )4
= 3)
[W c ]4 f cr 3 p 4co
fc and fcr are activity coefficient of carbon and chromium in liquid iron at 1wt % standard state. Hilly and
Kaveney proposed the following equation for distribution of chromium and carbon:
wcr 13800
log � � = − T + 8.76 − 0.925 log pCO 4)
wc
The effect of Ni
w 13800
log � wcr � = − T+4.21Wt %Ni + 8.76 − 0.925 log pCO 5)
c
Equations 4and 5 describes distribution ratio of Cr and c in Fe-Ni –Cr-C melt. Table shows the influence
wcr w
of temperature and pCO on the distribution ratio (𝑅𝑅) = �
wc
� without Ni and R1 = � wcr� in the presence
c
of 10Wt % Ni
The above observations suggest that high temperature is needed to remove carbon in presence of
chromium, if stainless steel is produced at atmospheric pressure. If reduced pressures are used; lower
temperature can cause oxidation of carbon.
Electric arc furnace was used to produce stainless steel by melting scrap of the desired composition. EAF
was used only as a melting unit.
Typically, charge consists of carbon steel scrap + stainless steel scrap +lime. The charge is melted in EAF
and after melt- down period, the melt contains around 10% Cr, all Nickel and carbon. Melt consists of
Fe- Cr –Ni –C alloy
Oxygen is blown onto Fe- Cr- Ni –C melt and basic Cr2 O3 slag forms. Initially chromium oxidizes until
bath temperature rises to 1800℃. Carbon oxidation occurs once the bath temperature rises to 1800℃
In the finishing stage, low carbon ferrochrome is added to make the chromium content of steel to a
desired value. The disadvantages with this technology are
Thus a technology which can use high carbon ferro- chrome and to decarburize the bath at selectively
lower temperatures would be required. If carbon is to be oxidized in preference to Cr at low
temperatures, a reduction in pressure of CO from 1 atmosphere to lower value would be required.
Reduction in pressure of CO can be achieved either by vacuum or by using a mixture of Ar + O2 . The
former one is vacuum oxygen decarburization (VOD) and the later is (AOD)
AOD Process
The process in carried out in a converter type of vessel. Vessel is lined with magnesite brick. A mixture
of argon +oxygen is injected through the tuyeres located on the side of the converter shell.
Fe-Cr- Ni-C alloy melt is prepared in EAF. Melt is charged in AOD vessel. High carbon-ferrochrome is
charged. In the initial stage a mixture of O2 : Ar in 3:1 ratio is blown through the side tuyeres. When
carbon reduces to 30% of the original value the ratio of O2 : Ar is changed to 2: 1 and blow is continued
to attain 0.09 to 0.12% C. First stage of blow generates sufficient amount of heat due to oxidation of Cr
and hence coolants are added (5% of the change). Stainless steel scrap is used.
In the final stage, the ratio of O2 : Ar is changed 1:3 to bring C to the desired value. Fe- Si is added to
recover Cr from slag and slag basicity is maintained at 1.5 to 2 by adding lime.
Slag formation and slag metal reactions are facilitated by argon stirring of the bath. The bath is
desulphurized to levels well below 0.015%.
References:
Contents:
Basis
CONARC
Basis:
• To develop ecological balance technology. Such a technology would require processing the raw
materials such that liquid products are discharged at the environmental temperature and waste
products are discharged in their harmless states. This requires integrating the concept of
recovery, reuse and recirculation within the process environment.
• To develop a process which is flexible to use varying proportion of metallic materials depending
on their availability. Converter steelmaking is based on hot metal.
• To develop technologies which are not electric energy dependent. Electric steelmaking is
dependent of availability of cheap electric power, though developments are made to use
chemical energy.
In the above concept, two technologies are worthwhile to mention: Energy optimizing furnace (EOF) and
CONARC (Converter + Arc furnace)
Figure 19.1 is a schematic sketch of an energy optimizing furnace (EOF). EOF is a combination of three
independent, interconnected reactors, namely furnace to produce steel, preheater to heat the scrap and
a recuperator to rcover waste heat and to reuse by heating oxygen.