To improve the utilization value of electric arc furnace dust (EAFD) containing zinc, the reduction behavior of non-agglomerate dust was investigated with carbon and ferrosilicon in an induction furnace. The experimental results show that when the temperature increases, the zinc evaporation rate increases. When the reducing agent is carbon, zinc evaporation mainly occurs in the range of 900–1100 °C. When the reducing agent is ferrosilicon, zinc begins to evaporate at 800 °C, but the zinc evaporation rate is 90.47% at 1200 °C and lower than 99.80% with carbon used as a reducing agent at 1200 °C. For the carbon reduction, the iron metallization rate increases with a rise in the temperature. When the reducing agent is ferrosilicon, with an increase in temperature, the metallization rate first increases, then decreases, and finally, increases, which is mainly due to the reaction between the metallic iron and ZnO. In addition, the residual zinc in the EAFD is mainly dispersed in the form of a spinel solution near the metallic phase.
For the collapse of the working layer of dry vibrating material during preheating, the four-strand tundish of a steel plant was taken as a prototype for numerical simulation. The software ANSYS was used to calculate the temperature field and stress and strain field on the working layer under three preheating stages through the indirect coupling method. The results show that during the preheating process, the temperature field distribution on the hot surface of the working layer gradually develops toward uniformity with the increase in preheating temperature. However, the temperature gradient between the cold and hot surfaces increases subsequently, and the highest temperature between the cold and hot surfaces reaches 145.31 °C in the big fire stage. The stress on the top of the working layer is much larger than in other areas, and the maximum tensile stress on the top reaches 39.06 MPa in the third stage of preheating. Therefore, the damage to the working layer starts from the top of the tundish. In addition, the strain of the area near the sidewall burner nozzle in the casting area is much larger than that in the middle burner area with the increase in preheating temperature. Thus, the working layer near the sidewall burner nozzle is more prone to damage and collapse compared with the middle burner nozzle.
The stability of chromium in stainless steel slag has a positive correlation with spinel particle size and a negative correlation with the calcium content of the spinel. The effect of heating time on the precipitation of spinel crystals in the CaO-SiO2-MgO-Al2O3-Cr2O3-FeO system was investigated in the laboratory. Scanning electron microscopy with energy-dispersive and X-ray diffraction were adopted to observe the microstructure, test the chemical composition, and determine the mineral phases of synthetic slags, and FactSage7.1 was applied to calculate the crystallization process of the molten slag. The results showed that the particle size of the spinel crystals increased from 9.42 to 10.73 μm, the calcium content in the spinel crystals decreased from 1.38 at% to 0.78 at%, and the content of chromium in the spinel crystal increased from 16.55 at% to 22.78 at% with an increase in the heating time from 0 min to 120 min at 1450 °C. Furthermore, the species of spinel minerals remained constant. Therefore, an extension in the heating time is beneficial for improving the stability of chromium in stainless steel slag.
On the basis of the Brody–Flemings model and modified Voller–Beckermann model, an analytical model of micro-segregation is established by considering the actual solidification cooling conditions of bloom. According to the developed model, the interdendritic solute distribution at the origin of the cracking gap is obtained. It is found that both phosphorus and sulfur have quite severe segregation, but both carbon and manganese have slight segregation; these results agree well with the semiquantitative analysis results of the scanning electron microscope (SEM). At the same time, the interdendritic segregation leads to an enhanced increase in the temperature range of crack formation; correspondingly, the possibility of cracking significantly increases and, thus, element segregation is the internal cause of crack formation. On the other hand, taking into account heat transfer, phase transformation, and metallurgical pressure, the strain of the solid shell is revealed through finite element software. When the solid shell thickness is equal to the distance of 90 mm between the opening point of the crack and the inner arc side, the tensile strain of the solid front is much bigger than the critical strain, which meets the external cause of crack formation; therefore, reasons for the cracking of blooms are successfully found.
The productivity of basic-oxygen-furnace (BOF) smelting process is directly affected by the slag-forming speed during the initial stage of converter. Therefore, it is essential to study the effect of different Cr2O3 content on the physicochemical properties of the primary slag in the smelting process of chromium-bearing semi-steel. In this work, Factsage8.1 software, X-ray diffraction (XRD), scanning electron microscope (SEM), energy dispersive spectroscopy (EDS) and a high-temperature melting point tester were used to study the effects of different Cr2O3 content on the melting temperature, solidification behavior, mineral composition, and other physicochemical properties of the CaO-SiO2-FetO system. The results showed that the melting temperature of slag samples increased from 1223 °C to 1354 °C as Cr2O3 increased from 0 wt% to 9.09 wt%. With the increase of Cr2O3, the content of CaFeSi2O6 decreased. Moreover, due to the addition of Cr2O3, the chromium-bearing spinel solid solution (Fe(Fe,Cr)2O4) began to form in the slag. Furthermore, Cr2O3 promoted the increase in the volume of free solid particles in the slag, resulting in an increase in slag viscosity. All in all, the increase of Cr2O3 content in the CaO-SiO2-FetO system will adversely affect the semi-steel steelmaking process.
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