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<p>Employing a mixed charge of hydrogen direct reduced iron (DRI) and scrap as iron-containing feedstock in electric arc furnace (EAF) steelmaking is expected to be one future trend toward achieving carbon-neutral and high-quality steel production. Therefore, a fundamental understanding of melting and refining process control in this process is increasingly desired. To achieve this, in this study, a phenomenological mathematical model to simulate steelmaking operations in an EAF with DRI and scrap mixtures is developed. The model integrates a materials balance module and a thermochemistry module and covers the main aspects of the EAF process including scrap and DRI melting, slag formation, carbon and oxygen injection, heterogeneous reactions, <i>etc</i>., enabling it to predict slag and steel composition in real time based on process conditions. With the aid of this model, the effects of shares of DRI in the feedstock matrix and DRI chemistry on the process dynamics are evaluated. The results indicate a well-calibrated strategy involving carbon and oxygen injection, as well as the use of DRI metallization and C content, should be implemented, so as to achieve optimal metallic yields while minimizing bath oxidation levels. The current model can serve as a valuable tool to determine this equilibrium and provide a knowledge base to assist in the design, operation, and optimization of EAF practices.</p>

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Simulation on Process Dynamics of Electric Arc Furnace Steelmaking with Mixed Charge of Direct Reduced Iron and Scrap

  • 期刊论文

  • 发表日期：

    2025年11月24日

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  • Mingming Li,
  • Pengbo Wang,
  • Ning Ma,
  • Lin Li,
  • Shiyi Chen,
  • Lei Shao,
  • Zongshu Zou,
  • Xinyi Wang

摘要

Employing a mixed charge of hydrogen direct reduced iron (DRI) and scrap as iron-containing feedstock in electric arc furnace (EAF) steelmaking is expected to be one future trend toward achieving carbon-neutral and high-quality steel production. Therefore, a fundamental understanding of melting and refining process control in this process is increasingly desired. To achieve this, in this study, a phenomenological mathematical model to simulate steelmaking operations in an EAF with DRI and scrap mixtures is developed. The model integrates a materials balance module and a thermochemistry module and covers the main aspects of the EAF process including scrap and DRI melting, slag formation, carbon and oxygen injection, heterogeneous reactions, etc., enabling it to predict slag and steel composition in real time based on process conditions. With the aid of this model, the effects of shares of DRI in the feedstock matrix and DRI chemistry on the process dynamics are evaluated. The results indicate a well-calibrated strategy involving carbon and oxygen injection, as well as the use of DRI metallization and C content, should be implemented, so as to achieve optimal metallic yields while minimizing bath oxidation levels. The current model can serve as a valuable tool to determine this equilibrium and provide a knowledge base to assist in the design, operation, and optimization of EAF practices.