Decarburization of ferrochrome and high alloy steels with optimized gas and slag phases towards improved Cr retention

Chromium is a high value metal and the retention of the same during the refining of high carbon ferrochrome as well as high alloy steel has significant economic and environmental impacts. The loss of chromium during the decarburization is generally minimized using argon-oxygen mixtures thereby reducing the oxygen partial pressure (PO2) of the oxidant gas. In the current study, experiments were carried out in an induction furnace and CO2 was introduced with the view to partly reduce PO2 and partly as an oxidizer. During these experiments, the decarburization of molten Cr-alloy was conducted using pure O2, pure CO2 or O2+CO2 mixtures. The results demonstrated that the Cr loss can be minimized under CO2 introduction. The kinetic analysis showed that the mass transfer is effective due to the production of 2CO gas molecules from one CO2 molecule during the reaction which will improve the stirring of the bath. Besides, CO2 reacts with carbon in melt is an endothermic reaction, introduction of CO2 could be a cooler during the refining process, hence the temperature could be controlled by controlling the diluting gas amount, in this case, the overheat of bath refractory could be prevented and the lifetime of refractory could be extended.


Introduction
Traditionally, O 2 is selected as an oxidizer for decarburization in ferrochrome refining process and also Electric Arc Furnace (EAF) process.However, as reported by earlier researchers, it is realizable to decarburize with CO 2 as well.The principle of decarburization of Fe-C melts using CO 2 has been expounded by Mannion and Fruehan [1].Their results showed that nearly one-fifth of CO 2 supplied was consumed during the decarburization reaction.Zughbi [2] reported higher decarburization rate and more vigorous reaction when O 2 was used as the oxidizing gas instead of CO 2 .Sain and Belton [3] have studied the decarburization of liquid iron by CO 2 at great length.CO 2 was also introduced into the argon-oxygen refining process by Heise et al. [4].
It is reported that the carbon removal efficiency in argon-oxygen decarburization process (AOD) was improved by using CO 2 in argon-oxygen mixtures.Some authors [5][6][7][8] also carried out the study on the surface decarburization of Fe-Cr-C melts.Besides this, there are some researchers who investigated as to how to reduce the Cr loss during ferrochrome refining and also the high alloy steel making process.AOD as a traditional and effective way is being used widely in the world.Steam (H 2 O) is another profitable alternative for Cr retention during AOD process according to UHT's (Uvån Hagfors Teknologi AB, Sweden) references and experience through its CLU technology [9,10].To the knowledge of the present authors, no systematic investigation has been carried out with respect to the simultaneous decarburization and Cr-loss in Fe-Cr-C melts with introduction of CO 2 .
In the present study, the Cr retention during M-LCFeCr making process and high alloy steel making process is investigated with introducing CO 2 in the gas system.

Theoretical analysis
The order of oxidation ability for O 2 , CO 2 and O in Fe-C melts is shown in Table 1.The overall chemical reaction of decarburization with CO 2 can be described by equation (1).In the present calculations, w[i] = 1% (Henrian) was chosen as the standard state of C and O .

Table 1
The oxidation ability for O 2 , CO 2 and O .

Reactions
No.
It is seen in Table 1 that CO 2 is a weaker oxidizing agent compared to O 2 .From a thermodynamic point of view, it is possible to use CO 2 as an oxidizer for decarburization, realizing that Cr will also be oxidized by CO 2 during this process from reaction (5).One point to be noticed is that reactions (1), ( 3), ( 4) and ( 5) are exothermic while reaction ( 2) is an endothermic reaction.With mixing CO 2 in the gas system, the temperature of the bath could be decreased and also controlled in some extent.
Except for the possibility to use CO 2 as a decarburizer, the Cr retention during the decarburization process needs to be considered as well.It is also well known that, in order to prevent Cr in the molten metal phase from oxidation, at the same time decarburization, reaction (6) given below should be prevented.This can be illustrated by introducing the parameter, referred to in the present work as the 'critical temperature Tc' for Cr and C. Critical temperature is the temperature at which r 6 Δ G =0 .3CO(g)+2Cr=Cr O (s)+3C (6) The standard states of Cr and C were chosen as w[i] = 1% (Henrian).In the case of Cr 2 O 3 in the slag, pure substance standard state was taken.The standard state of 1 atm was for CO. 0 r Δ G of equation ( 6) is given by equation (7) e can be obtained from literatures [11,12,13].
The value of the Gibbs energy change for reaction (6) thus is given by: The critical temperature T c was calculated at different situations and the result is presented in Table 2. Cr can be kept in the metal bath only if the temperature of the melt exceeds T c .This indicates that a lower value of T c is better for the retention of Cr if the bath temperature is constant.that Tc increases with the increasing of Cr content when C content is a constant.Further, Tc decreases with the increasing of C content when Cr content is stable.Thus, if the temperature of the melt is kept constant, Cr-loss will increase with the progress of decarburization.Or in case the temperature is kept constant, if the partial pressure of CO is decreased, the Cr will be kept in the melt and the C will be removed.To realize decrease p CO , dilute gas such as Ar could be used (the principle to AOD process) from the thermodynamics point of view.
Besides thermodynamic aspects, kinetic aspects should also need to be considered.Ar introduction could increase the stirring of the bath, hence increase the contact between carbon and Cr 2 O 3 that eventually is oxidized, thereby restoring the Cr back to the melt.In the present study, CO 2 was used as the stirring gas.It should be noted that the activity of Cr 2 O 3 was assumed to be unity in the above calculations.If the activity of chromium oxide is decreased due to the dissolution in the slag, chromium oxidation will be favored.
Fig. 1 The effect of C and Cr contents on Tc.
Another aspect to be considered with respect to the reduction of Cr 2 O 3 formed by the carbon dissolved in the steel is the formation of 3 molecules of CO gas according to reaction (12): The formation of 3 molecules of CO by the reduction of Cr 2 O 3 in the melt is similar to the oxidation of Cr in the melt as represented by reaction (5).The CO gas bubbles thus formed either by reaction (5) or by reaction (12) will not further react with the components in the metal bath.
One of the significant differences between O 2 and CO 2 injections is that, for every molecule of O 2 injected, 2 moles of C from the melt can be removed; however, for every mole CO 2 , only one carbon atom in the melt will be removed.Accordingly, in order to achieve the same metal composition at the end of the blowing, one needs to blow twice the amount of CO 2 compared to O 2 .It may be also noted that for every CO 2 bubble injection, two CO bubbles are formed; the number of CO bubbles will be twice that corresponding to O 2 injection.This can facilitate good mixing between metal and slag phases leading subsequently towards a near-equilibrium situation, corresponding to equations ( 12) and ( 13).
In the above considerations, the temperature of the metal bath was assumed to be constant.In reality, decarburization with O 2 injection (reaction (1)) would be exothermic while, reaction (2) will be endothermic.
Thus, decarburization with CO 2 would require additional energy input in order to keep the temperature of the metal bath constant.
For refining of ferrochrome or high alloy steel, the temperature must be controlled during decarburization period, to ensure that it is neither too low to lead Cr oxidized strongly nor too high to lead furnace lining damaged.The real production experience showed that the temperature around 1700℃ is optimum according to Rick [14], and this temperature is normally used in high alloy steel refining as well as HCFeCr refining.

Experiment
A series of experiments were carried out in an induction furnace with samples masses of 1kg metal and with a slag phase above.The schematic diagram of experimental set-up is illustrated in Fig. 2. The slag sample was melted at 1773 K in an induction furnace.The amount of slag added was approximately 5% of the metal mass.The "mother alloy" was produced in significant amounts by pre-melting alloy mixture of targeted composition in an induction furnace in order to get homogenous alloy.It was then cut into even pieces of 1 kg and was used in each experiment.
During the decarburization running, Ar atmosphere was introduced during the melting of the steel.After totally melted, oxidant gas was blown into the liquid metal at 1873K.Samples of the steel melt were taken at appropriate time intervals using quartz sampler tubes of I.D. 6mm and quenched in cold water.The samples were analyzed to obtain carbon and chromium compositions.Fig. 3 The relationship between Cr and C during refining process with the initial carbon content at 0.3wt% It is illustrated clearly in Fig. 3 that, the rate for Cr loss with decarburization process while blowing pure O 2 is slightly larger than that blowing pure CO 2 , when the initial carbon content in the melt was 0.3wt%.This indicates that CO 2 may have superiority in Cr retention.However, comparing the slopes of those above curves starting from carbon 0.3wt% to 0.15wt%, there are very similar.Hence, the CO 2 introduction seems have no impacts on Cr saving during low carbon level.This needs future investigation.

Results and Discussions
Fig. 4 The relationship between Cr and C during refining process with the initial carbon content at 3.0wt% It is seen in Fig. 4 that, when blowing pure CO 2 , the Cr content almost kept constant during decarbuzaiton, while with oxygen blowing, the Cr loss is maximum 2%, with high initial carbon content (approximately 3.0wt%).That indicates the advantage to use CO 2 for Cr retention, especially with high initial carbon content melt.That indicates CO 2 may have big advantages for decarburization of high carbon ferrochrome (HCFeCr) to make medium carbon ferrochrome (MCFeCr) or low carbon ferrochrome (LCFeCr) in ferroalloy industry.

The effect of CO 2 in Cr-retention at low initial carbon content
The same initial C content was taken to investigate the Cr loss in pure O 2 and CO 2 at low carbon contant (around 0.25%).For 100%O 2 , the initial steel composition was C:0.257wt%,Cr,11.1wt%; for 100%CO 2 , the initial composition of steel was C:0.253wt%,Cr,8.5wt%.The Cr-loss in these two situations is shown in Fig. 5.It is obvious that the Cr-loss rate in 100%O 2 and 100%CO 2 is almost the same at the beginning 7 mins.But with the progress of refining, Cr-loss rate with blowing 100%CO 2 is less than that blowing 100%O 2 .The maximum Cr-loss with blowing 100%CO 2 is about 30% at 17.5min, at the same time, blowing 100%O 2 , the Cr-loss even reach 75%, which is more than twice that of blowing 100%CO 2 .This indicates that, O 2 oxidation ability is stronger than CO 2 .And if one considers both decarburization and Cr-oxidation, Fig. 6 may illustrate clearly.
It can be found, the decarburization rate by blowing O 2 is about twice of that blowing pure CO 2 during 3.5min to 14min.while the rates in both cases are fairly constant after about 3.5 min.With respect to Cr-loss rate, the rate with blowing pure O 2 is about 1.6 times that of blowing pure CO 2 when the gas was injected into the bath for 3.5min.With the progress, rate of blowing pure O 2 is seen to increase sharply even over 1.4g/min, but the Cr-loss rate is almost constant at about 0.5g/min.This would imply that when blowing CO 2 , the Cr-loss is around 1/3 of the value corresponding to O 2 blowing.However, the decarburization rate with O 2 is just around 2 times of that with CO 2 .That indicates CO 2 is good for keeping Cr inside the steel for the same decarburization level.Fig. 6 The decarburization rate and Cr-loss rate when blowing pure O 2 and pure CO 2

The utilization ratio of O 2 and CO 2 in decarburization process
For blowing CO 2 , the effective part which is used in decarburization and Cr oxidation is O, as shown in equation (14).Hence, for blowing pure CO 2 , the effective part of CO 2 (CO 2 can be calculated as ) was taken to plot.The amount of effective part of gas (O 2 ) react with metal was calculated and plotted in Fig. 7 and Fig. 8 for two different initial carbon content melts.However, if consider the overall gas utilization (effective parts used for reaction), the utilization ratio of CO 2 is more than O 2 , especially in the first 7.0min, almost all the effective part of CO 2 is used for oxidizing C and Cr, but just half of O 2 is used for C and Cr oxidation, the rest may have been used for oxidizing Fe or escaped unreacted.
For high initial carbon content, the utilization of gas is also investigated and illustrated in the following figures.for oxidizing C and only a minor part is used for oxidizing Cr for both two gas cases.However, for blowing pure O 2 , at the beginning 24mins, the gas amount to react with Cr and C are very similar, but for blowing pure CO 2 , the gas amount oxidizing C is much larger than that reacts with Cr, which indicates that CO 2 is much more effective in decarburization at high initial carbon content, and also efficient for Cr retention.

Conclusions
1) The experimental result shows that CO 2 is effective for Cr retention, especially for high initial carbon content situation.CO 2 can be as diluting gas to reduce partial pressure of oxygen.The endothermicity of the Boudouard reaction can be advantageously used to control the bath and control temperature, which would extend the refractory life.
2) For low initial carbon content, the overall utilization ratio of CO 2 is higher than O 2 , especially at the initial stage of decarburization, almost all the effective part of CO 2 is used for oxidizing C and Cr, on the other hand, for O 2 as decarburizer, approximate half of O 2 is used for C and Cr oxidation.
3) For high initial carbon content, CO 2 could be an effective diluting gas for decarburization, since in this situation, CO 2 is very effective for decarburization.At lower initial carbon content, the superiority of CO 2 for decarburization and Cr retention is not obvious.

Future work
1) The slag now used is synthesized in order to protect the Al 2 O 3 crucibles, however, in the real production, MgO or MgO-Cr 2 O 3 lining are normally used in FeCr refining process and high alloy steel refining process.
Hence, the slag composition is different and needs to be optimized so that the activity of the oxidation product, viz.Cr 2 O 3 would be high in the slag phase.In this case, Cr loss could be reduced.
2) Based on positive results obtained now, pilot plant trials are currently being planned at Uddeholms AB, Hagfors, Sweden.In order to maximize decarburization, a computer program based on a kinetic model was developed as part of this work.This is being adopted to control the gas composition and flow rate.The program will also take into account the extra energy need in the process in view of the endothermicity of the above reaction, by controlling the ratio of O 2 +CO 2 .This also would enable the prevention of overheating and would have a positive impact on the refractory life.These trials are expected to be followed by plant trials at Uddeholms AB, where the process is expected to be implemented.
3) For high carbon ferrochrome refining, the use of CO 2 as a decarburizer needs to be future-investigated.The current results show that CO 2 is more efficient at higher carbon content.For high carbon ferrochrome, the carbon content is around 7wt%, hence the decarburization with CO 2 appears to be promising

Fig. 1
Fig. 1 illustrates the variation of T c with respect to Cr and C contents.From this figure, it can be seen clearly

Fig. 2 A
Fig.2 A schematic drawing of the induction furnace

Fig. 5
Fig.5The Cr-loss during refining when blowing pure O 2 and pure CO 2

Table 2
The critical temperature T C for different [C] and [Cr].

Table 3
presents a selected part of the results from the significant number of experiments carried out in the present work.The initial carbon contents of FeCr alloy are selected as 0.3mass% and 3.0 mass%, and the results obtained are presented in this table.Only pure O 2 and pure CO 2 were tested in current experiments.The experiments were carried out in two different scales, one with 500g materials and the other with1000g materials, both at 1873K.

Table 3
The Cr and C change during refining process

The relationship between C and Cr content during the refining process
The overall utilization of the gases at high initial carbon content shown in Fig.8(a) and Fig.8(b), is similar to that decarburization of low initial carbon content.The effective part of pure O 2 used for reacting with Cr and C is just half the gas, the rest is oxidizing Fe or just flows away, however, for pure CO 2 , almost 100% of the effective gas is used for Cr and C reaction, in this case, around 100% CO 2 is used for decarburization since Cr is almost not oxidized.It is also seen in above figures that, at high initial carbon content, most of the gas is used