Evolution and Control of Non-Metallic Inclusions in Steel During Secondary Refining Process

doi:10.11900/0412.1961.2021.00227

Acta Metall Sin

2022, Vol. 58

Issue (1): 28-44 DOI: 10.11900/0412.1961.2021.00227

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Evolution and Control of Non-Metallic Inclusions in Steel During Secondary Refining Process

ZHU Miaoyong(

), DENG Zhiyin

School of Metallurgy, Northeastern University, Shenyang 110819, China

Cite this article:

ZHU Miaoyong, DENG Zhiyin. Evolution and Control of Non-Metallic Inclusions in Steel During Secondary Refining Process. Acta Metall Sin, 2022, 58(1): 28-44.

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Abstract

The problem of inclusions is one of the key concerns in the production process of high-quality special steel grades. This study summarized the main inclusion types, and their formation, evolution, and removal mechanisms during the secondary refining process. Meanwhile, combined with studies and practices of the authors, some control measures of inclusions were also discussed. According to this study, the inclusion types after refining are generally different from that of initial deoxidation products, and the formation and evolution of these inclusions are closely related to the dissolved elements in liquid steel, e.g., Ca, Mg, and Ti. Although sometimes the compositions of the inclusions are the same, their different shapes and distributions can also lead to different grades of inclusions depending on the micrographic method. Overall, solid inclusions can be easily removed compared with liquid inclusions, and Al₂O₃ and MgO·Al₂O₃ inclusions have a higher removal efficiency in contrast to liquid CaO-Al₂O₃ system inclusions. Refining slag, refractory, and ladle glaze may have a great impact on the control of trace elements and evolution of inclusions in liquid steel; therefore, suitable slag basicity and slagging operations are important during the refining process. In the case of Al-killed steel grades, slag with a basicity of 4-7 leads to a good deoxidation result, while the slag basicity adjustment during the refining process is generally negative for the control of inclusions in Si-Mn-killed steel grades. Moreover, special attention should be given to the use of CaO-containing refractory. High-quality clean alloys and a suitable alloying stage can also be beneficial for the control of trace elements and the removal of inclusions in the alloys. Furthermore, during the refining process, excessive stirring should be avoided to reduce the flush-off of ladle glaze, and inclusion modification technologies should be considered with precautions. Some methods, e.g., the control of Ca content, the prevention of slag entrainment, and the removal of ladle filler sands, are helpful for the control of micro-inclusions. Recent studies on the inclusions appropriately explained many phenomena in metallurgical processes, indicating some new directions for inclusion control. In the near future, certain mechanisms (e.g., the growth of CaO-Al₂O₃inclusions) still need further investigation, and some new technologies are also required to solve the known problems, e.g., complete removal of ladle filler sands.

Key words: inclusion steel refining evolution mechanism removal mechanism control technology

Received: 27 May 2021

ZTFLH:

TF769

Fund: National Natural Science Foundation of China(U20A20272)

About author: ZHU Miaoyong, professor, Tel: (024)83686995, E-mail: myzhu@mail.neu.edu.cn

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	Zhiyin DENG

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https://www.ams.org.cn/EN/10.11900/0412.1961.2021.00227 OR https://www.ams.org.cn/EN/Y2022/V58/I1/28

Table 1 Main types of inclusions found in different steel grades at different steel plants^[2-19]

Fig.1 Illustration of evolution of inclusions in typical Al-killed steel grades
(a-c) conventional Al-killed steel (d-f) medium-Mn steel (g-k) Ti-bearing alloyed steel (l) Ti-bearing ULC steel (m) Ca treatment

Fig.2 SEM images of typical inclusions in BOF crude steel (a-c) and Al-killed steel (d-h)^[23]
(a) CaO-SiO₂-FeO inclusion (b) CaO-SiO₂-FeO + (Mg, Fe, Mn)O dual-phase inclusion
(c) (Fe, Mn)O inclusion (d) Al₂O₃ inclusion clusters
(e) singular Al₂O₃ inclusion (f) MgO·Al₂O₃ inclusion
(g) CaO-Al₂O₃(-MgO) inclusion (h) CaO-Al₂O₃(-MgO) + MgO·Al₂O₃ dual-phase inclusion

Fig.3 Elemental mappings of a typical Al₂O₃-(Fe, Mn)O inclusion^[34]

Fig.4 Elemental mappings of spinel layer formed at the edge of an alumina inclusion^[41]

Fig.5 SEM image (a) and elemental line scans (b) of a MgO·Al₂O₃ inclusion after Ca treatment^[36]

Fig.6 Illustration of a refining ladle in industry

Table 2 Contact angles between inclusions and liquid steel at 1600^oC^[69,70]

Fig.7 Schematics of motion of solid (a) and liquid (b) inclusions at steel-slag interface (t—time, t _s—separation time, z—displacement, u _∞—terminal velocity, u _I—velocity, z(t)—displacement at time t, r—radius, P—pressure)

Fig.8 Effect of basicity on the value of $a A l 2 O 3 2 ? / ? a S i O 2 3$ ^[74] ( $a A l 2 O 3$ —activity of Al₂O₃, $a S i O 2$ —activity of SiO₂, w—mass fraction)

Fig.9 Iso-activity lines of oxygen (10^-4) in CaO-SiO₂-Al₂O₃-5%MgO system calculated by FactSage (1600^oC, R—slag basicity)^[48]

Table 3 Melting points (T _m)^[38] and T.[Ca] / T.[O] values of different inclusions

Fig.10 Iso-activity lines of Al (10^-4) in CaO-SiO₂-Al₂O₃-5%MgO system calculated by FactSage (1600^oC)^[48]

Fig.11 Elemental mappings of a macro-inclusion originated from ladle glaze^[102]

Fig.12 SEM image of TiO _x -SiO₂-Al₂O₃ base phase in ladle filler sand grains (a) and EDS result (b)^[105]

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