A mathematical simulator for the EAF steelmaking process using direct reduced iron

A mathematical simulator for the melting operation of direct reduced iron in electric are furnaces (EAF) has been developed. The simulator takes into account the changes of physical properties of slag with time as well as the operating aspects of the process by using different input types of the raw materials into the furnace. Control of the bath oxidation is performed through the injection of carbon fines in the slag. Cost-optimized mass and energy balances are employed as generators of initial and boundary conditions to start the solution of a set of ordinary differential equations whose solution allows to know the dynamic changes of temperature and metal and slag chemistry with time. Simulation results indicate that the final bath oxidation level is more dependent on the process routes than on the quality of the direct reduced iron (DRI) being melted. High carbon wettability by slags and basic slags are the most suitable conditions to promote iron oxide reduction in order to maintain a low bath oxidation. Process outputs influenced by complex EAF operations using different DRI metallizations, different sequences for feeding raw materials in the furnace, injection of carbon and oxygen and different types of inputs are well predicted by the present mathematical simulator.