05- New and Future Steel Technologies Using Mn - K Ichikawa Nippon Steel Corp
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Transcript of 05- New and Future Steel Technologies Using Mn - K Ichikawa Nippon Steel Corp
8/3/2019 05- New and Future Steel Technologies Using Mn - K Ichikawa Nippon Steel Corp
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Development of Japan’s Refining
Technologies in the Past and Future
2004.6.2
By Kaoru Ichikawa Nippon Steel Corporation
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2. Behavior of Mn in the Steel-making process
3. History of Process Improvement and
Influence on Manganese (1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment
(4) MURC process
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
5. Future Development
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China
JapanJapanU.S.A.
Germany Korea
1950 60 70 80 82 84 86 88 90 92 94 96 98 00 02 03
200
180
160
140
120
100
80
60
40
20
0
Total
1000
800
600
400
200
0
220
Japanese peak 120 million tons 1973
C r u d e s t e e
l p r o d u c t i o n
( m i l l o n t o n s / y e a r )
T o t a l p r o
d u c t i o n ( m i l l o n t o n s / y e a r )
8/3/2019 05- New and Future Steel Technologies Using Mn - K Ichikawa Nippon Steel Corp
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1960 65 70 75 80 85 90 95 2000
1,000
800
600
400
200
0
500 600
5
ChahgesChahges in the consumption of in the consumption of
steel products in JAPANsteel products in JAPAN
T h e p e r
T h e p e r - - c a p i t a c o n s u m p t i o n o f s t e e l
c a p i t a c o n s u m p t i o n o f s t e e l
p r o d u c t s ( k g p e r p e r s o n )
p r o d u c t s ( k g p e r p e r s o n )
The average consumption in the advancedThe average consumption in the advanced
industrial nations is approx. 500 to 600 kgindustrial nations is approx. 500 to 600 kg
per person.per person.
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1000
100
10100 1,000 10,000 100,000
GDP US dollar per person
Korea Japan 575kg
Russia 173kg
Thailand 121kg
China
132kg
India 27kg
GermanyU.S.A.
Average
135kg
T h e p e r
T h e p e r - - c a
p i t a c o n s u
m p t i o n o f s t e e l
c a
p i t a c o n s u
m p t i o n o f s t e e l
p r o d u c t s ( k g p e r p e r s o n )
p r o d u c t s ( k g p e r p e r s o n )
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Crude steel 2001
TotalTotal 846846 million tonmillion ton
AsiaAsia 363363 million tonmillion ton 4242
10344 152
JapanJapan KoreaKorea ChinaChina
OthersOthers
496496
The steel demand
900
700
500
300
100
362 422 449
A s ia A s ia 2 42 4
T he w or ld t o ta l increa se
d
T he w or ld t o ta l increa se
d 1313
2001 2002 2003 2001 2002 2003 2001 2002 2003 2004
73 72 7238 44 44
174 211 232 255
m i l l i o n t o n s
Japan Korea China
Consumption of steel productConsumption of steel product million tonsmillion tons
million tonsmillion tons
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1997 98 99 2000 01 02 03 05
6
5
4
3
2
1
01995 96 97 98 99 2000 01 02
30
20
10
0
16
12
8
4
0
The outputs of automobilesThe outputs of automobiles The output of electric appliancesThe output of electric appliances
Automobile Automobile
BusBus Truck Truck
F o r e c a s t
F o r e c a s t
Air conditioners Air conditioners
RefrigeratorsRefrigerators
ChinaChina
JapanJapan
ChinaChinaJapanJapan
48 50
110 112 127 146 164 216 420 600
5761
70
109 m i l l i o n
m i l l i o n
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1,100
1,000
900
800
700
600
500
400
300
200 C r u
d e s t e e l p r o d u c t i o n
m i l l i o n t o n s / y e a r
1960 70 80 90 2000 2010 2020
Crude steel productionCrude steel production
ForcastForcast made at the endmade at the end
of the 20th centuryof the 20th century
Forecast after China,a newForecast after China,a new
growing market, is takengrowing market, is takeninto accountinto account
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2002
2010
2020
2030
2040
2050
Forecast for the world populationForecast for the world population Forecasts for the crude steel productionForecasts for the crude steel production
0 20 40 60 80 100 0 0.5 1 1.5 2
Asia Oceania
North America
South
AmericaEurope Africa
(billion people) (billion tons)
0.9
O n l y t h e
p o p u l a t i o n g r o w t h i s
t a k e n i n t o a c c o u n t
The economicgrowth of each regionis also takeninto account
1.35 1.95
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China
JapanJapan
U.S.A.
Germany Korea
1950 60 70 80 82 84 86 88 90 92 94 96 98 00 02 03
200
180
160
140
120
100
80
60
40
20
0
Total
1000
800
600
400
200
0
220
Japanese peak 120 million tons 1973
C r u d e s t e e l p r o d u c t i o n
( m i l l o n t o n s
/ y e a r )
T o t a l p r o
d u c t i o n ( m i l l o n t o n s / y e a
r )
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(1957~1970) (1971~1980) (1981~2000)
Top Blow Top Blow
converter converter
degassing degassing degassing degassing degassing
degassing Inclusion Inclusion
control control
Top-bottom
comvined converter
Top-bottom
comvined converter
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0
1
2
3
4
5
1 9 7 4
1 9 7 6
1 9 7 8
1 9 8 0
1 9 8 2
1 9 8 4
1 9 8 6
1 9 8 8
1 9 9 0
1 9 9 2
1 9 9 4
1 9 9 6
1 9 9 8
2 0 0 0
2 0 0 2
M n a l l o y u n i t ( k g
/ t )
HC-FeMnMC,LC
Si-Mn
M.Mn
Fe-Si
0
1
2
3
4
5
6
7
1 9 7 4
1 9 7 6
1 9 7 8
1 9 8 0
1 9 8 2
1 9 8 4
1 9 8 6
1 9 8 8
1 9 9 0
1 9 9 2
1 9 9 4
1 9 9 6
1 9 9 8
2 0 0 0
2 0 0 2
M n u n i t (
k g / t )
TotalHC-FeMn
MC,LC Fe-Mn, M.Mn, Si-Mn
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1. Introduction
3. History of Process Improvement and
Influence on Manganese (1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment
(4) MURC process
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
5. Future Development
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Process Flux & oxygen % content in Fe
[C] [Si] [P] [S] [Mn] Temp.
(℃)
BF 1530
(dS) CaO、 4.5 0.4 0.1 0.02 0.3
Hot Metal Mg or Na2CO3
Pretreatment (dP) CaO、
Fe-Ore、O2 4 tr 0.02 0.005 0.2 1350
BOF CaO、MgO
Mn-Ore
Fe-Ore、O2 0.05 tr 0.02 0.005 0.15 1650
Secondary
Refining Alloy
0.001 tr 0.005 0.001 0.15~
Product ~0.3 ~0.5 ~0.03 ~0.03 1.5 -
Reaction Condition
Basicity PO2 Temp.
Decarburization - High -
Dephosphorization High High Low
Desulfurization High Low High
Reduction of MnO High Low High
An example of the steel making method &
acceleration conditions for respective reactions.
C + 1/2O2 = CO P + 5/4O2 + 3/2CaO = 1/2Ca3(PO4)2
S + CaO = CaS + 1/2O2
Mn + 1/2O2 = MnO
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[C] [Si] [Mn]
[C] [Si] [Mn][C] [Si] [Mn]
HCFeMn LCFeMn Si-Mn
kg/heat HCFeMn LCFeMn Si-Mn
kg/heat HCFeMn LCFeMn Si-Mn
Yield 95 95 95 % kg/heat
95 95 95 %
95 95 95 %
Chemical content (%)
C Si Mn
HCFeMn 6.85 0.00 74.50
LCFeMn 0 .86 0.00 81.00
Si-Mn 2.20 14.50 60.70
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Mn + 1/2O
2 = MnO
(%MnO) 1
[%Mn] Tlo = -1.79 + 1.07×log (%T.Fe) + 3.980× -0.048×log (%CaO/%SiO2)
1
55 1 (%MnO)
71 1000 [%Mn]
Mn yield (%) =1 + × × × Slag volume
× 100
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1. Introduction
2. Behavior of Mn in the Steel-making process
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment
(4) MURC process
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
5. Future Development
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Process Bottom tuyere Bottom gas type Bottom gas flow
construction rate(Nm3/t/min)
LD-OB Double-pipe tuyere O2,Ar,CO2,N2,LPG 0.10 to 0.60
LD-CB Small-diameter pipe CO2,N2,(O2) 0.01 to 0.10
assembly plug
Fig. Relation between turndown free oxygen and turndown carbon intop-blown, bottom-blown, and combined-blown converter 4).
O2
CO2
N2
LPG
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O2
CO2
N2
LPG
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1. Introduction
2. Behavior of Mn in the Steel-making process
(1) Top-and-Bottom blowing converter
(3) LD-type hot metal pretreatment
(4) MURC process
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
5. Future Development
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82 84 86 88 90 92 94 96 98 00 02
Nipponn Kimitsu ★ ●
Steel Yawata ★ ●Oita ★ ▲ ●
Nagoya ★ ●
Muroran ★ ●
JFE Chiba ★
Mizushima ★Keihin ▲ ●
Fukuyama ▲ ●
Sumitomo Kashima ★ ●
Wakayama ★ ● ●
Kobe Kakogawa ★ ★
Kobe ●
★:TPC
▲:Ladle
●:Converter
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LD Hot metal pretreatment
process and LD-OB process(1981) (1989)
Monthly crude steel production 200,000 407,000
capacity (t/furnace/month)
Hot metal pretreatment ratio (%) 0 69
Availability (%) 55.2 85.5
Tap-to-tap time (min) 34 28
Furnace life (heats) 1,795 5,340
Molten steel yield (%) 93.6 95.1
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0
10
20
30
40
5060
70
80
90
100
0 20 40 60 80 100 120
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1. Introduction
2. Behavior of Mn in the Steel-making process
(1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(4) MURC process
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
5. Future Development
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Free Exhaust Stirring Oxygen Oxygen Scrap Initial
boad gas energy supplying gas ratio melting investment
treatment rate cost
Injection Process Small Simple Low Low Low Impossible Low
Top-and-bottom Large OG High High High Possible High
blowing converter System
Slag (T.Fe) De-Si Addition of Slag Slag
basicity content before fluorspar foaming utilization
de-P
Injection Process 4-8 2-5 Imperative Necessary Small Difficult
Top-and-bottom 1-2 7-18 Not Not Large Easyblowing converter Imperative Necessary
Process
Treatment condition
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Manganese use in the LD-type process
For manganese use in the LD-type process,
manganese yield improvement
due to the decreased slag volume in the converter
can be obtained in the same way as using conventional technology.
However, a decrease in Mn during dephosphorization
cannot be avoideddue to increased %T.Fe and lowered basicity
during dephosphorization.
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The [Mn] value
goes down.
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1. Introduction
2. Behavior of Mn in the Steel-making process
(1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
5. Future Development
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Slag
Solidification
ext
chSpeciality of MURC Process
・Low Basicity, High (T.Fe), Low Temperature →High Efficiency De[P]
(CaO/SiO2≦2),(T.Fe)≧8%,(~1350℃)
・High Gaseous Oxygen Ratio,
Low HMR Operation
・Slag Hot Recycle→Reduction of Slag
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0
20
40
60
80
100
120
Conventional MURC No
Recycle
MURC
T o t a l C a O C
o n s u m p t i o n
( C
o n v e n t i o n a l
B l o w = 1 0 0 % )
Hot Metal [Si]=0.42%
Low C Steel
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20
30
40
50
60
70
80
90
Conventional MURC No
Recycle
MURC
B O F S l a g ( k g / t )
Hot Metal[Si]=0.42%
Low C Steel
(Exclude Metal ,Water )
M l i th MURC
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Manganese loss in the MURC process
Manganese loss in the MURC process increases
as a result of low basicity and high %T.Fe
during the dephosphorization process.
In addition, with dephosphorization and decarburization
being operated continuously,
the carry-over of phosphorus into the decarburization process increases,
requiring light dephosphorization treatment
in the decarburization process.
Since the smelting reduction of manganese ore
becomes difficult with increased manganese loss,
the turn-down [Mn] is consequently reduced
compared to that in the conventional pretreatment process.
Manganese alloy in the LD type pretreatment &
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Manganese alloy in the LD-type pretreatment &
MURC process
In the LD-type pretreatment method,
priority is given to using scrap and reusing or reducing slag,
which is demanded by today’s society.
On the other hand,
the MURC process focuses on improving heat loss
and shortening the process time.
Neither technology emphasizes
reducing the volume of the Mn alloy used,
So there is little or no reduction
compared to the conventional pretreatment.
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1. Introduction
2. Behavior of Mn in the Steel-making process3. History of Process Improvement and
Influence on Manganese (1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment (4) MURC process
(1) Automobile sheet steel
(2) Plate products
5. Future Development
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Steel product needs
• Market demands related to steel products are becoming
increasingly strict.
• There has been continuous cost reduction in the refining
process and cost increase due to improved and upgraded
quality of steel products.
→We shall examine the changes in improved and upgraded
steel products using automobile sheet steel and heavy plate products as example.
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1. Introduction
2. Behavior of Mn in the Steel-making process3. History of Process Improvement and
Influence on Manganese (1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment (4) MURC process
(2) Plate products
5. Future Development
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Application of TS 590 Mpa or
higher steel to automobile 13).
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Conventional high strength sheet steel
for automobiles used to be solid
solution-hardened steel or
precipitation-hardened steel withalloy added.
Currently, high strength steel products whose
microstructure isreinforced for greater strength have been used.
(DP steel, TRIP steel)
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Yield Tensile Elon-
Type of steel C Si Mn Ti strength strength gation(Mpa) (Mpa) (%)
A Mild steel 0.05 0.01 0.24 - 241 384 43
B Solid solution 0.08 0.02 1.46 - 370 487 30
hardened steel
C DP steel 0.05 0.89 1.25 - 432 618 27
D Precipitation 0.09 0.01 0.80 0.07 539 636 22
hardened steel
E TRIP steel 0.15 1.48 0.99 - 510 644 37
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1. Introduction
2. Behavior of Mn in the Steel-making process3. History of Process Improvement and
Influence on Manganese
(1) Top-and-Bottom blowing converter
(2) Hot metal pretreatment
(3) LD-type hot metal pretreatment (4) MURC process
4. Steel product needs (1) Automobile sheet steel
(2) Plate products
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C l i
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Conclusion
As for manganese use in the process in view of the above prospects,
we can assume that the smelting reduction of manganese ore
in the converter will not be actively employed in the futuresince it decreases the scrap usage rate, increases slag generation
and results in a low yield level of manganese;
this is on the condition that the Fe-Mn price remains very economical.
As long as the main technological concern in the refining process
focuses on improving the main reaction, namely dephosphorization,
the supply of manganese that has different reactive characteristics
will take the form that adds alloys.
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The advantages of steel materials over other materials
include volume, price, strength, toughness and versatility.
For the above sheet steel and plate products,the need for higher grade, higher quality,
and meeting strict requirements will grow in the steel market.
The base for developing higher grade, higher quality steel products
will be the addition of alloys to steel materials.
Fe-Mn alloys, especially low carbon alloys,
will be in much greater demand from now.
References
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