Development of digital twins and optimization of resource-efficient steelmaking technologies

Abstract

In this study, mathematical models, algorithms and software for dynamic simulating of processing technologies in a ladle furnace and vacuum degassers were developed, and a new method for optimizing ladle processing technologies for various steel grades was created. Physicochemical models were developed based on the laws of conservation of mass and energy, as well as the principles of non-equilibrium thermodynamics. The developed software allows us to calculate the basic characteristics of steel refining processes, such as temperature and chemical composition of slag and steel melts, kinetics of refining processes, economic indicators, energy and resource efficiency of technologies. To validate the software, the results of industrial hits and the results of the control of metal and slag were used. Nonmetallic inclusion analysis procedures have been developed using the fractional gas analysis method to control of steel cleanness and to detect and adjust the sources of inclusions formation at all stages of ladle furnace steel processing. For various steel grades, it was shown that it is possible to successfully optimize technologies using a combination of developed modeling software and fractional gas analysis. A mathematical model for the interaction of a high chromium iron base melt with a low temperature plasma was developed. Comparison of the experimental results in DC arc furnace with calculating data is in a good agreement.