Review: Effect of Reoxidation on the Non-Metallic Inclusion in Molten Steels in Tundish

doi:10.11900/0412.1961.2024.00178

Acta Metall Sin

2025, Vol. 61

Issue (10): 1485-1501 DOI: 10.11900/0412.1961.2024.00178

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Review: Effect of Reoxidation on the Non-Metallic Inclusion in Molten Steels in Tundish

DUAN Shengchao¹, LIU Zhentong², KANG Jun³, BAI Chengfeng³, WEN Jian³, LIU Gang³, ZHANG Lifeng¹(

)

1 School of Mechanical and Materials Engineering, North China University of Technology, Beijing 100144, China
2 School of Mechanical Engineering, Yanshan University, Qinhuangdao 066004, China
3 Jinhai Stainless Steel Co. Ltd., Wuzhou 543002, China

Cite this article:

DUAN Shengchao, LIU Zhentong, KANG Jun, BAI Chengfeng, WEN Jian, LIU Gang, ZHANG Lifeng. Review: Effect of Reoxidation on the Non-Metallic Inclusion in Molten Steels in Tundish. Acta Metall Sin, 2025, 61(10): 1485-1501.

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Abstract

The tundish is the final metallurgical reactor through which molten steel flows, and it significantly affects the quality of steel products. With the increasing demand for high-purity steel, the role of tundish metallurgy has attracted greater attention. This study systemically examines the causes of reoxidation in molten steel, the effects of air absorption during nonsteady-state teeming, tundish cover flux interactions, and refractory materials during the steady-state teeming process. These factors were analyzed for their influence on the chemical and inclusion composition of different steel grades. In addition, measures to mitigate the reoxidation of molten steel in tundish were analyzed. The results demonstrate that the three factors causing the reoxidation of molten steel occur simultaneously. However, in the nonsteady-state teeming stage, air absorption in the molten steel is the primary cause of reoxidation. Conversely, in the steady-state teeming stage, tundish cover flux and refractory materials are the main reasons. When reoxidation occurs due to gas absorption by molten steel, the gas absorption rates varies for different steel compositions. In the stable teeming of molten steel, the high content of SiO₂ in the rice husk ash (RHA) in the top layer of the double-layer cover flux gradually dissolves in the high-basicity cover agent in the bottom layer. At the slag-steel interface, the self-dissolution reaction (SiO₂) = [Si] + 2[O] occurs, resulting in the loss of Al, Ti, and Mn elements in the molten steel, whereas the Si content, total oxygen (T.O) content increase, and the composition, size, and number density of the inclusions change. Carbothermal reactions between Al₂O₃-SiO₂-C refractories and molten steel can generate oxidizing CO gas, which is the main cause of the reoxidation of ultra-low carbon Ti added Al-killed steel. In addition, unstable oxides such as Cr₂O₃, MnO, SiO₂, and FeO present in the gunning material and ladle filler sand can cause serious steel reoxidation. The reoxidation of steel and dissolution of SiO₂ in the underlying cover agent can be mitigated by designing a new type of tundish cover flux to replace the RHA. Nitrides can be used in the nozzle material to reduce the release of the oxidizing gas CO, preventing nozzle clogging. Microporous magnesia-refractory materials provide strong heat insulation and slag resistance.It can absorb thermal stress and reduce the initiation and expansion of cracks in refractory materials. Therefore, microporous magnesia refractories have good application prospects as tundish lining materials.

Key words: tundish reoxidation refractory material non-metallic inclusion thermodynamics

Received: 23 May 2024

ZTFLH:

TF746

Fund: National Key Research and Development Program of China(2023YFB3709901);National Natural Science Foundation of China(52404335)

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https://www.ams.org.cn/EN/10.11900/0412.1961.2024.00178 OR https://www.ams.org.cn/EN/Y2025/V61/I10/1485

Fig.1 Schematic of the physicochemical reactions occurring in the molten steel flow through the tundish^[8]

Fig.2 Factors responsible for the reoxidation of molten steel in tundish^[9] (Δ[O] represents the amount of oxidation of the molten steel by the factors in the initial teeming stage and the stable casting stage)
(a) oxidation by air at the ladle shroud
(b) oxidation by air from the surface
(c) oxidation by ladle well-packing material
(d) oxidation by tundish cover powder

Fig.3 Mechanism illustrations of the dynamic behavior at a steel/slag interface under the effect of chemical reactions^[30]

Tundish cover powder	Steel composition	Experimental method	Ref.
(39.5-62.5)CaO-(2.7-22.2)Al₂O₃-(2.6-47.4)SiO₂	Ultra-low carbon steel	The industrial trials were carried out at the No.5 continu-ous caster at Mizushima Works in Kawasaki Steel Corp-oration	[27]
52CaO-35Al₂O₃-13SiO₂ 50CaO-50SiO₂-100SiO₂	Al-killed steel	Reoxidation of Al-killed steel by slag and air was investigated in laboratory experiments and industrial trials in 85 t tundish at Sumitomo Metal Industries	[31]
*	Non-killed and Al-killed steels	The industrial trials were conducted in 60 t tundish at Nippon Steel Corporation	[26]
RHA + (46-50)CaO-(42-45)Al₂O₃-3SiO₂-2Fe₂O₃- (1.8-2.5)TiO₂	Ti-bearing Al-killed ultra-low carbon steel	The industrial trials were conducted at Tata Steel	[20]
26.8CaO-42.3Al₂O₃- 27.6SiO₂	Ti-stabilized ultra-low carbon steel	45 g steel covered with 40 g tundish slag was held in an alumina crucible at 1823 K	[24]
RHA + 45CaO-35Al₂O₃- 10SiO₂-5MgO-5CaF₂	Al-killed Fe-C-Si steel	500 g of steel and 50 g of slag were placed in a MgO crucible and heated to 1823 K (R = 0.14, 0.26, 0.38, and 1.0)	[8]
RHA + 55CaO-35Al₂O₃- 4SiO₂-4MgO	Al-killed Fe-C-Si steel	500 g of steel and 50 g of slag were placed in a MgO crucible and heated to 1823 K (RCA = 0.5, 0.75, 0.83, 0.87, and 0.90)	[28]
50CaO-30Al₂O₃-10SiO₂- 10MgO-(5, 10)Cr₂O₃	Al-killed YT01 steel	The Al-killed steel was held in a MgO crucible at 1923 K for 30 min and then 20 g of slag with various Cr₂O₃ contents was added	[29]
73CaO-25SiO₂-(1-15)FeO-1MnO	Ultra-low carbon steel	The slag-metal reactions between 30 g pre-melted slag and 100 g of sample were conducted in a zirconia crucible at 1853 K	[25]
44.2CaO-44.1Al₂O₃- 6.0SiO₂-2.68MgO-1.17TiO₂	Ti-bearing Al-killed ultra-low carbon steel	400 kg of the basic tundish flux was added to the surface of the molten steel in the 70 t tundish, and then 60-80 kg of rice hull ball was added to the tundish flux	[21]
RHA + 45.65CaO-22.88Al₂O₃-20.75MgO-2.84SiO₂	Si-Mn killed SAE 1055 steel	150 g steel and 20 g tundish slag (5 g RHA) were acco-mmodated in an Al₂O₃ crucible at 1853 K	[32]
53.5CaO-41.5Al₂O₃-5MgO and 47.5CaO-47.5SiO₂-5MgO	Si-killed 304 stainless steel	600 g of 304 stainless steel and 50 g of slag were cont-ained in a MgO crucible at 1773 K	[33]
RHA, RHA + 51.1CaO- 43.3SiO₂, and RHA + 52.6CaO-40.7Al₂O₃	Si-killed 316L stainless steel	600 g of 316L stainless steel was placed in a MgO crucible at 1773 K and then 45 g of tundish flux was quickly added to the surface of the molten steel	[34]

Table 1 Summaries of previous studies on the reoxidation of molten steel by tundish flux^{[8,20,21,24-29,31-34]}

Fig.4 Reaction mechanism causing the early-stage clog deposit growth

Fig.5 Microstructure of the interface between Ti-stabilized ultra-low carbon steel and MgO-based gunning material^[49](P $O 2$ —oxygen potential)
(a) oxygen from refractory (trapped air in pores, reducible FeO_x and SiO₂ oxides)
(b) molten steel with a low oxygen content (around 10^-11 Pa)
(c) FeO_x at the refractory/steel interface

Tundish refractory	Steel composition (mass fraction / %)	Main conclusion	Ref.
Al₂O₃-SiO₂	Ni-Fe alloy	The substitute of mullite to SiO₂ mullite of the refractory bonding matrix or the use of alumina bricks can avoid the reoxidation of the melt and intense inclusion formation	[52]
GM, MgO boards, and dry powder	0.45C-3.1Si-0.4Mn-8.5Cr-0.25Ni	An oxidized steel layer can be formed at the steel/refractory lining interface	[53]
MgO, Al₂O₃, MgO + 2MgO·SiO₂ GMs	Ti-stabilized ultra-low carbon steel	The large difference in oxygen potential between refractory and steel phase leads to the formation of (Mg, Fe)O layer ( $P O 2$ = 10^-11 Pa); The thicker layer was formed using MgO-based GM compared with Al₂O₃-based GM	[49]
MgO- and Al₂O₃-based GMs	Ti-stabilized ultra-low carbon steel	The oxidation capacity of MgO GM with 10SiO₂-6FeO was higher than that of Al₂O₃ GM with 3.3SiO₂ + 2FeO	[24]
MgO-CaO and MgO-based GMs	Si-Mn-killed SAE 1055 steel	The GM with the reducible oxides SiO₂ and FeO was responsible for providing oxygen and causing reoxidation of the molten steel	[32]
MgO- and Al₂O₃-based GMs	Ti-stabilized ultra-low carbon steel	The MgO GM represented a stronger oxidizing capacity, while Al₂O₃ can improve the cleanliness of the molten steel	[51]
High-silica tundish refractory (66MgO-27SiO₂-4FeO-3CaO)	Fe-2Al alloy	The content of the oxidizing oxides in the refractory should be reduced to avoid the loss of Al in the alloy	[54,55]

Table 2 Summaries of reoxidation of molten steel caused by refractory material of tundish^{[24,32,49,51-55]}

Fig.6 Changes of inclusion composition in steel^[60]
(a) Ruhrstahl-Heraeus degasser (RH furnace) out (b) tundish (c) slab (d) plate

Fig.7 Characteristics of typical CeAlO₃ clusters at the defect of slab samples with reoxidation^[69]

Table 3 Summaries of inclusion transformation caused by molten steel reoxidation^{[8,28,34,44,60,64,69-81]}

Fig.8 Oxide stability diagram of Fe-Al-Ti-O system at 1540 ^oC^[82]

Fig.9 Changes in number density of inclusions in the steel with reaction time after various flux additions^[34]
(a) RHA only
(b) RHA + CaO-SiO₂ (RHA + Flux A)
(c) RHA + CaO-Al₂O₃ (RHA + Flux B)

Fig.10 Dispersions of the dissolved oxygen in the molten steel during unsteady processes^[85] (t—time)
(a) t = 10.2 s (b) t = 40.2 s (c) t = 70.2 s

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