Optimization of Oxygen Injection Conditions with Different Molten Steel Levels in the EAF Refining Process by CFD Simulation

Abstract

In electric arc furnace (EAF) steelmaking, oxygen jets play a crucial role in controlling stirring ability, chemical reactions, and energy consumption. During the EAF lifetime, refractory wear leads to a decrease in the molten steel level and an increase in the nozzle-to-steel distance, thereby negatively affecting the overall energy efficiency of the process. The objective of this study is to optimize the energy efficiency of the EAF refining process by adjusting the nozzle flow conditions and conducting an analysis of jet performance using computational fluid dynamics (CFD) simulation. Three types of injection jets were considered: the conventional jet, the CH4 coherent jet, and the CH4 + O2 coherent jet. The findings reveal that the shrouded flame of the coherent jet enhances jet performance by maintaining the maximum velocity, extending the potential core length, and increasing the penetration depth in the molten steel bath. To maintain the jet performance in response to an increased nozzle-to-steel distance resulting from refractory wear, transitions from the conventional jet to the CH4 coherent jet and the CH4 + O2 coherent jet are recommended once the nozzle-to-steel distance increases from its initial level of 1000 mm to 1500 mm and 2000 mm, respectively.

Theoretical Energy Consumption Analysis for Sustainable Practices in Iron and Steel Industry

“…During that period, researchers concentrated their efforts on enhancing the thermal and exergy efficiency while minimizing energy losses in individual pieces of equipment, guided by the principles of the first and second laws of thermodynamics. It has been emphasized that effective measures to reduce energy loss and enhance efficiency involve adjustments to material structure, technological parameters, structural parameters, and so on [10][11][12]. For instance, Feng et al [13] optimized the sintering cooling machine, aiming to maximize exergy output.…”