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Optimizing Flux Addition in BOF Steelmaking

This study focuses on optimizing the flux addition process in the Basic Oxygen Furnace (BOF) steelmaking to address high flux consumption and refractory erosion issues. By re-engineering the flux charging sequence, the research achieved significant reductions in lime and calcined dolomite usage, resulting in substantial cost savings and improved refractory integrity. The modifications also enhanced steel quality and operational efficiency, demonstrating the importance of precise flux control in steelmaking processes.

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pawan
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12 views2 pages

Optimizing Flux Addition in BOF Steelmaking

This study focuses on optimizing the flux addition process in the Basic Oxygen Furnace (BOF) steelmaking to address high flux consumption and refractory erosion issues. By re-engineering the flux charging sequence, the research achieved significant reductions in lime and calcined dolomite usage, resulting in substantial cost savings and improved refractory integrity. The modifications also enhanced steel quality and operational efficiency, demonstrating the importance of precise flux control in steelmaking processes.

Uploaded by

pawan
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as RTF, PDF, TXT or read online on Scribd

Abstract

The Basic Oxygen Furnace (BOF) process is a cornerstone of primary steelmaking, where fluxes such as
lime and calcined dolomite (CD) play critical roles in refining and refractory protection. However,
persistent issues of high flux consumption and accelerated refractory erosion—particularly in the right
trunnion area—necessitated a strategic reassessment of flux addition practices. This study investigates
and implements a change in the flux charging process aimed at improving flux utilization and enhancing
the refractory profile of the converter.

Root cause analysis identified two primary issues: (1) suboptimal kinetics of dephosphorization despite
favorable thermodynamics at the end of the blow, and (2) localized refractory erosion driven by uneven
MgO distribution due to poor flux reactivity and delayed dissolution. In particular, late-stage flux
dissolution limited early slag-metal interaction, reducing the time window for efficient phosphorus
removal. Additionally, charging asymmetry and poor foaming conditions led to MgO-deficient, highly
erosive slag near the right trunnion, accelerating refractory wear.

To address these issues, the flux addition sequence was re-engineered to ensure earlier and more
uniform flux dissolution, particularly in the pre-decarburization phase. This enabled earlier formation of
a high-basicity, MgO-saturated slag, improving both dephosphorization kinetics and refractory
protection. The modification also balanced slag chemistry spatially across the converter, minimizing local
erosion zones.

Tangible outcomes of the intervention were significant. Average lime consumption reduced by 1 tonne
per heat, equating to an annual saving of approximately 20,000 tonnes and ₹20 crores. CD consumption
dropped sharply due to improved refractory integrity, reducing gunning mass usage by 60% and
extending campaign life. Increased converter availability enabled up to two additional heats per day,
contributing to an estimated ₹30 crores annual EBITDA improvement.

Intangible benefits included improved endpoint phosphorus levels, reducing reblow frequency and
enhancing steel quality. These changes shortened tap-to-tap times, increased average heat weight, and
reduced operational overheads such as oxygen usage and sample analysis frequency.
This work demonstrates that precise control over flux addition timing and distribution, grounded in
metallurgical and process analysis, can yield substantial operational, economic, and quality
improvements in BOF steelmaking. It highlights the importance of integrating kinetic control with spatial
slag behavior to unlock hidden efficiencies in legacy processes.

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