Simulation of Ladle Steelmaking Process: Effective Equilibrium Reaction Zone Model Using FactSage Macro Processing

Approximately 10–15% of the world’s steel production is derived from small industries. While ladle furnaces contribute to maintaining a generally good quality of refined steel, new challenges arise, especially when striving for very low sulfur percentages in steel. To address this, the study explores the impact of process parameters such as aluminum, silicon, and basicity in reducing sulfur content. Three interconnected equilibrium/adiabatic stoichiometric-reactor-based approaches describe the overall ladle steel-making process. The macro-programming facility of FactSage™ software was used to determine the refining behaviors of the ladle steel-making processes. The model’s predicted endpoint, manganese, sulfur, oxygen, and aluminum content, agreed with plant data. This efficient model is a valuable guiding tool for ladle steelmaking industries with a 10–15 ton capacity.