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7.1 Introduction
Pre-treatment of hot metal is the adjustment of the composition and temperature of blast furnace
produced hot metal for optimal operation of the oxygen converter process; as such, it is one of the
interdependent chain of processes that constitute modern steelmaking1, Fig. 7.1. When taken to the
extreme case, the converter process function is reduced to scrap melting and carbon reduction subsequent to the prior removal of silicon, phosphorus and sulfur in preparatory steps under thermodynamically favorable conditions. An important benefit of removing phosphorus and sulfur from
the hot metal prior to the oxygen converter process is the ability to produce steels with phosphorus and sulfur contents lower than otherwise achievable without severe penalty to the converter
process. Silicon removal is beneficial to the converter to reduce the chemical attack on the basic
refractory lining and to allow the use of only minimal amounts of slag-making fluxes, thereby
maximizing process yield.
Hot metal pre-treatment by North American and European steel producers presently is focused on
desulfurization due to the common use of relatively low phosphorus containing iron ores.
In a unique approach to pre-treatment, ISCOR, in South Africa, installed a hot metal mixer
equipped with channel inductors to provide electrical energy to heat the liquid, and thereby raise
the scrap melting capability of the steel plant.
Details of the process steps introduced above are provided in the following sections.
413
1957~1970
De-S
BOF
(LD)
BOF
(LD)
BOF operation
start
1971~1980
1981~ present
De-S
De-Si
De-Si
De-P
De-S
Combined
blowing
process
Combined
blowing
process
De-S
De-S
Vac-treatment
Vac-treatment
Vactreatment
Development of
hot metal desulphurization
&
Vacuum treatment
of molten steel
Hot metal
desiliconization
&
Combined
blowing
1st period
De-S : desulphurization
De-Si : desiliconization
De-P : dephosphorization
2nd period
Vac-treatment,
De-S,
Inclusion
control
Division of refining
function
3rd period
De-C : decarburization
Vac-treatment : Vacuum treatment
Fig. 7.1 Changes in refining functions in the Japanese steel industry. From Ref. 2.
results were attained48 by the addition via subsurface injection of the reagents in dedicated vessels, such as oversized torpedo or submarine cars. This brought on the use of a variety of chemical
reagents, including soda ash (sodium carbonate), which also provides for significant removal of
sulfur. When using iron oxides for desiliconization, it is essential to separate, i.e., remove, the
process slag before the hot metal is desulfurized as this operation requires low oxygen potential for
efficient performance. It is important to recognize that phosphorous removal occurs only in hot
metal containing less than 0.15% Si, additionally, phosphorus held in the slag could be subject to
reduction, i.e., reversal, into the hot metal if it were present during desulfurization. An interesting
technical development was the combination of dephosphorization and desulfurization in a single
vessel whereby5 phosphorous is reacted with the oxidizing reagents as they rise in the liquid and
sulfur is removed by the top slag in the vessel, Fig. 7.2.
Desiliconization and dephosphorization are accompanied by losses of carbon from the hot metal
and evolution of CO2 from carbonate reagents.4 Thus, control strategies such as addition of coke
breeze9 or equipment accommodations must be made in the reaction vessel and gas capture systems to contain foaming and flame evolution. In the recent timeframe, environmental considerations over disposal of sodium-containing slags has forced the use of limestone based reagents,
often mixed with iron ore or sinter fines and delivered with oxygen, the latter used to diminish the
thermal penalty from the pre-treatment process. Oxygen consumption in these process steps is
illustrated in Fig. 7.3.
414
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
NISSHIN
SMI
Planned or NSC
under
construction NKK
KSL
SMI
KSC
NKK
In operation NSC
Kure
(No. 2 BF)
Oita
(No. 2 BF)
Fukuyama
(No.2 BF)
Keihin
(No. 1 BF)
Kokura
(No. 2 BF)
Kimitsu
(No.2, 4 BF)
Yawata
(No. 4 BF)
Fukuyama
(No. 4 BF)
Chiba
(No. 6 BF)
Kashima
(No. 3 BF)
Wakayama
(No. 4 BF)
Kobe
(No. 3 BF)
Nagoya
(No. 2 LD plant)
Keihin
Wakayama
Kakogawa
NKK
SMI
KSL
Muroran
Yawata
Sakai
Nagoya
(No. 1 LD plant)
Fukuyama
Kashima
NSC
NKK
SMI
NSC
NISSHIN
NKK
SMI
SMI
NSC
Kure
KSL
SMI
NKK
KSC
NSC
KSC
NSC
Oita
Nagoya
(No.2 LD plant)
Keihin
Chiba
(No. 3 LD plant)
Wakayama
Kokura
Kakogawa
Kimitsu
Nagoya
(No. 1 LD plant)
Muroran
Yawata
Chiba
(No. 1 LD plant)
Dephosphorization in
transport vessel
(lime-based flux)
Dephosphorization equipment
Yawata
(No. 1 LD plant)
Fukuyama
Kashima
Kashima
Dephosphorization in
Desiliconization in
Desiliconization
transport vessel
blast furnace runner
transport vessel
(soda ash)
__________________________________________
____________________________________________________________________________
Desiliconization equipment
Table 7.1 Hot Metal Pre-treatment Facilities in Japan (1983). From Ref. 3.
KSL
KSC
Chiba
(No. 2 LD
plant)
Mizushima
Kobe
Dephosphorization in
furnace for exclusive
use (converter)
415
Hopper
Dispenser
O2
N2
Soda Ash
Hopper
Millscale
Hopper
Lance Elevating
Device
Fig. 7.2 Equipment for concurrent dephosphorization and desulfurization. From Ref. 7.
Feeder
Conveyer
O2 Lance
Injection
Lance
Dust Collecting
Hood
Ladle
Dephosphorization
Desiliconization
Si
C
P
010 0.5
Decarburization
4 0.08 0.4
3 0.06 0.3
Si
(C
on
ve
nt
(O
io
RP
2 0.04 0.2
1 0.02 0.1
0
na
l)
Si
0
0
1 2
20
40
60
80
Fig. 7.3 Changes in silicon, phosphorus and carbon contents of iron in each stage of steelmaking. From Ref. 4.
In some plants, the silicon and phosphorus removal steps occur in full size oxygen converter vessels and the resulting carbon containing liquid is transferred, after separation of the low basicity
primary process slag, into a second converter, Fig. 7.4, for carbon removal by oxygen top blowing.4,7 In this sequence, the slag from the second vessel is used as a starter slag for the first step.
In a way, this is todays equivalent of the former open hearth process, which provided for flushing
of the initial silica and phosphorus rich slag and thus allowed the use of hot metal made from phosphorus bearing ores for production of what was then considered low phosphorus steels.
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
Blast
furnace
Blast
furnace
desiliconization
Na2CO3
dephosphorization
desulfurization
Na, V, P
recovery process
metal flow
with slag
slag flow
with small
amount of
slag
a combined blowing
converter
a combined blowing
converter
Fig. 7.4 Refining process based on soda ash treatment. From Ref. 8.
Initially these technologies were used to help the steelmaker, but, in time, it was recognized11 that
significant cost savings and production increases in ironmaking would result if sulfur limits formerly imposed on the blast furnace operation were lifted. In most North American steel plants, the
hot metal leaves the blast furnace containing 0.040%0.070%S, while the oxygen converters are
charged with hot metal containing as little as 0.010%0.001%S, to conform to limits on steel composition set by caster operations and final product quality requirements.
The importance of sulfur management and the huge costs involved have led to worldwide efforts
to develop and implement an array of different desulfurization technologies. The different reagent
and delivery systems in use are the result of local economic and environmental factors and the preferences of technical and operating management at the individual plant sites.
The following sections address the main chemical reactions for sulfur removal from hot metal, the
range of process permutations, the specifics of reagent delivery systems, the importance of reaction
vessel selection and of slag management issues as these topics bear on a well-functioning system.
(7.3.1)
Mg(s) + S MgS(s)
(7.3.2)
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
417
CaC2 + S CaS(s) + 2C
(7.3.3)
(7.3.4)
(7.3.5)
(7.3.6)
(7.3.7)
Initially, most plants relied on reaction 7.3.1, that is, the addition of soda ash (Na2CO3) at the blast
furnace cast house or at the steelworks while filling iron transfer ladles. This approach was abandoned as process control and environmental management were very difficult. In Europe and Japan,
mechanical stirrers (KR) were introduced into the blast furnace runners12, Fig. 7.5, and later for
use in hot metal transfer ladles13, Fig. 7.6. In the U.S. and Canada, the next step was dependent on
reaction 7.3.2 with the use of Magcoke (a product made by filling the pores of coke with magnesium and submerging this material into the hot metal in a sequence of multiple dunks). Results
were reproducible11, but, attainment of sulfur contents of less than 0.020% was costly in reagents
and process time. Capture of the copious magnesium fumes was nearly impossible without total
building evacuation.
Direction of stirring
Desulfurizing agent
Iron inlet
Point at which
desulfurizing
agent is added
Stirrer
Iron outlet
Fig. 7.5 Plan (left) and elevation (right) views of a unit for continuous desulfurization of iron. From Ref. 12.
Impeller
Particles of
desulfurizing agent
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
0.06
Mg ocm (%)
0.05
0.04
0.03
0.02
0.01
0
0.005 0.010
0.020
0.030
0.040
2.4
1
2
1.6
0.8
1200
1300
1400
1500
Temperature (C)
A critical step in process development was adoption of subsurface pneumatic injection of calcium
carbide powder15 (reaction 7.3.3) and of pulverized lime16 (reaction 7.3.4) or combinations, i.e.,
mixtures, of pulverized magnesium and lime (reaction 7.3.5). Because calcium carbide is inert, it
is difficult to distribute it throughout the liquid; to improve on this, one of two reagents is added
(,1520%) to create surface and stirring: limestone, which cools the liquid or diamid lime, which
is less endothermic. The latter version, known as CaD, was developed by SKW in Germany.
An important improvement came in the development of co-injection technology17: the controlled
mixing in the transport line of reagents supplied separately, Fig. 7.9. This technique, now in universal use, allows for a wide array of reagent combinations and permits independent adjustment of
the rates of the delivery of the reagents during the process, Fig. 7.10. This is most useful for magnesium based systems wherein splash and fuming during lance insertion and removal can be kept
to a minimum by starting and stopping magnesium reagent flow with the lance tip at the deepest
immersion in the hot metal. Another advantage is that the rate of delivery of the magnesium can
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
419
Skim
pulpit
Mg
Desulf.
pulpit
Mg
Lime
N2
Environmental
Skim
weighing
Tilting
stand
Mg (90%)
No. 2
Pulverized
lime No. 1
Pneumatic
stocking
0.50
0.40
Mg (10% MgO)
0.30
0.20
0.10
10
0.60
0.50
0.40
Mg
Soda ash
CaD
CaD
0.30
CaD
0.20 only
0.10
0
0
4
5
6
7
Injection time (min)
420
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
10
100
Mg
Injection rate
(kg/min)
3
50
7.3
5
6.5
.010
.020
.030
.040
.050
.060
A variant to the use of reactive agents like calcium carbide and magnesium is the use of lime powder either preceded by addition of aluminum2729 to the hot metal (reaction 7.3.6), or lime delivered with organic stirring agents such as natural gas16, 30 and/or solid hydrocarbons.31 The latter,
used as ground solid hydrocarbons, has been adopted to improve mixing even for magnesium based
reagents. With the use of aluminum, CaO?Al2O3 globules form which have a large solubility for
sulfur.32 Recently, in the U.S., desulfurization by injection of prefluxed 2CaO?Al2O3 has been
introduced with some commercial success (reaction 7.3.7). Although these reagents have lower unit
cost that carbide or magnesium, there is a limitation shared with lime systems; the greater mass of
reagent needed increases the time required for treatment and for the follow on raking step.
Two other methods for delivery of desulfurization agents into hot metal transfer ladles are worthy
of note. One approach, paralleling the use of cored wires for steel ladle treatment, is to feed magnesium cored wire33 at high rates to reach the ladle bottom for release of the reagent at maximum
depth. Magnesium in this form is far costlier than as an injectable solid, albeit the delivery system
is simpler to operate and maintain. Another approach, with somewhat larger implementation34,35,
known by the commercial name ISID, consists of feeding the reagents through a rotatable bayonet
system installed low in the wall of the hot metal transfer ladle, Fig. 7.12. Maintenance concerns
and cost have limited broad implementation of this technology.
421
1.
5.
4.
2.
3.
1. Storage silo.
3. Transport gas.
5. Ladle.
1. Before injection
3. End of injection
containers of limited capacity (20,000 kg each). Thus, to provide the capability to move this material in bulk, the industry developed a 90% Mg10% lime product that is flowable and can be delivered and stored in bulk trailers. Calcium carbide also must be kept from the moisture in air and is
transported and stored in bulk, sealed, pneumatic system equipped trailers. Salt-coated magnesium
is relatively impervious to moisture and generally is stored in bulk trailers as well.
An important adjunct to facilitate the use of pulverized materials such as lime and calcium carbide
has been the development of a technology for improvement of the flowability of these materials by
application of silicone oil based flow aids during pulverization.36 Powders prepared in this manner
can be delivered by dense phase injection techniques, which minimize the amounts of reagent and
iron droplets carried out of the liquid by the transport gas (e.g., for lime, transport line loading of
2 kg/l of gas). This allows delivery of injection reagents at rates of 50 kg/min through an 18mm
transport line.
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
100
75
50 (%)
25
180
170
160
150 (tons)
140
130
120
110
1540
1510
1480 ( C)
1450
5
10
15 20 25 301 5
November
10 15 20 25
December
30 1 5
1420
10 15 20
January 1983
furnace slag can cause sulfur reversals in the case of carbide based reagents. Furthermore, the postreaction slags are viscous and stick to the roof and sides in the submarine fleet, reducing holding
capacity.37 Over-treatment was the rule as the submarine ladles were treated some time prior to
their arrival at the melt shop and the coordination of their use for an intended product order.
Most shops changed to transfer ladle treatment to resolve these issues. The hot metal carrying
capacity of the submarine fleet increases due to elimination of slag build ups on the sub roofs37
and refractory wear is reduced, Fig. 7.13. Other problems associated with submarine ladle treatment include relatively poor mixing caused by the shape of the elongated bottle configuration and
the relatively shallow liquid depth. In the BOF transfer ladle, reagent efficiency of magnesium is
increased by the greater depth of lance immersion, which provides longer residence time for the
magnesium bubbles to travel to the surface. The major benefit of treatment in the transfer ladle
rather than in the submarine ladle is that it provides the opportunity to treat individual hot metal
charges to specific sulfur levels set by the requirements of the intended steel grade.
423
Gunning
Fig. 7.14 Illustration of a transfer ladle slag stirring lance. From Ref. 39.
During raking the post-treatment slag will take with it a significant metallic content (approximately
40% by weight)38, this can represent a yield loss of nearly 1%. Methods to minimize this loss
include the use of dense phase injection (to minimize the volume of gas for delivery of the injected
powders), and the addition of a fluxing agent, ,5% CaF2 or Na2CO3 to the desulfurizing reagents,
to produce a less viscous liquid slag for release of the iron globules. A further help is to provide a
small amount of gas bubbling39 (Fig. 7.14) during the raking process; this promotes flotation of
the slag towards the lip of the ladle and thereby reduces the number of strokes required for slag
removal.
Typical figures for slag removal are in the range of 1525 kg/ton hot metal for most U.S. shops.
Two viscosity related factors combine to make the quantity of slag raked from transfer ladles
dependent on hot metal temperature16, Fig. 7.15: colder hot metal appears to hold more entrained
blast furnace slag and the retention of iron droplets in slags increases as temperature drops. The
trend shown in Fig. 7.15 is typical for most BOF shops. Disposal of the spent slag usually is by
mixing it into the blast furnace slag management system despite the remaining unused sulfur holding capacity.23 In some plants special controls are in place to cope with the effect of remaining
unreacted reagents such as carbide or soda ash. This is not an issue with magnesium or lime.
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
100
80
+2s
60
40
-2s
Avg
20
0
1200
1250
1300
1350
1400
Lances typically are constructed of lengths of square steel tubing which contain the transport
pipe(s). These assemblies are then cast within a refractory mold and cured in temperature controlled drying ovens. The cross sectional shape may be square or round with an area of 4050 cm2
(68 in2). The refractory typically is high alumina.
A recent development directed at increasing the injection rate of magnesium containing combinations, without causing otherwise intolerable violence at the surface of the metal in the transfer
ladle, is to use two transport lines contained within a single lance each fed by a separate injection
materials source. The outlet nozzles are positioned to deliver the reagent at 30 from the vertical
on opposite sides of the lance. It is also possible to use two separate lances immersed into the metal
"Hockey stick"
lance
"Lazy L"
lance
Vertical
lance
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
425
at the same time. These approaches have reduced injection time by 40,50% without increasing
iron losses to the ladle slag or reduction in reagent efficiencies.
Hot metal s
.020
(after injection)
.015
Following skim
.010
.005
0
+1s
.013
1s .012
-1s
Before skim
.006
1s .003
-1s
The method for determination of endpoint sulfur is, in part, a function of the precision required at
the individual melt shop and other operating considerations. Gas combustion methods (Leco) and
optical emission spectrometers (OES.) are used commonly. Many shops have these instruments at
the treatment sites for rapid determination of results.
Optical emission spectrometers have demonstrated sufficient precision for determination of ppm
concentrations of sulfur in hot metal provided the disk samples obtained for analysis are sound and
prepared properly. Pits, holes and cracks will affect the results, as will surfaces with improper texture and/or flatness. OES determination has the advantage of providing silicon and manganese
analysis for use in the furnace charge model-a significant benefit when erratic blast furnace
operations result in varied hot metal chemistry.
The gas combustion method is recognized as probably the most accurate for determination of sulfur (and carbon) due to ease in achieving appropriate sample integrity. Prevention of process slag
entrapment in the pin sample is the greatest concern. Properly designed immersion samplers
inserted quickly to sufficient depth will provide slag-free samples. The latest Leco CS determinator is advertised to have a precision of 0.15 ppm.
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
.040
.030
.020
.010
.008
.006
.004
.003
.002
.001
0.050
CaD + 5% Na2CO3
0.010
0.005
CaD + Mg + Na2CO3
0.002
0
0.2
0.4
0.6
0.8
1.0
CaD (Kg/t)
Mg contained (kg/tHM)
Fig. 7.18 Typical reagent consumptions for desulfurization by co-injection. Left: lime-Mg, (lime containing 6% spar). From
Ref. 19. Right: carbide-Mg. From Ref. 21. Refer to Fig. 7.10 for blow patterns
Yield
Labor
7.3.10 Economics
Fig. 7.19 presents a breakdown of the cost components
for a typical transfer ladle hot metal desulfurization
operation.
Lances, gas
Fig. 7.19 Relative cost components for desulfurization of hot metal. Yield refers to loss of hot metal
during slag raking.
Modern facilities are generally fully automated to control the operation from the start of treatment to finish.
Powder initiation and lance insertion are automatically
controlled along with lance withdrawal after the predetermined amount of reagent has been injected. Reagent
rates may be adjusted during treatment by controlling
injection tank pressure or transport line throat diameter. In addition to the automatic functioning, the controlling computer provides for process data capture
and storage. Real-time graphics provide information
on process efficiency and dispenser performance to
aim standards. Typical, for a well-controlled operation,
is to achieve within 0.002%S of aim at end points
ordered <0.003%S.
427
7.5 Acknowledgments
The guidance and help of many friends
and colleagues are much appreciated, in
particular Professor Toshishiko Emi, Dr.
Paul Nilles, and Robert G. Petrushka and
C. J. Bingel of LTV Steel.
References
1. T. Emi, Proceedings, The Howard Warner International Symposium on Injection in
Pyrometallurgy,(1996) TMS, 19.
2. T. Shima, Proceedings of The Sixth International Iron and Steel Congress, (Nagoya: 1990),
ISIJ, Vol. 3:1.
3. S. Ishihara, Nippon Steel, address given at 1984 IISI Technology Committee Meeting.
4. K. Sasaki et. al., Steelmaking Proceedings, Iron and Steel Society 66 (1983): 285.
5. M. Wada et. al., Proceedings, Scaninject IV Conference (1986): 19:1.
6. S. Yamato et. al., McMaster University Symposium on Hot Metal Preparation (1983): 218.
7. K. Yamada et. al., Proceedings, McMaster University Symposium on Hot Metal Preparation
(1983): 245.
8. T. Ueda et. al., Proceedings, McMaster University Symposium on Hot Metal Preparation
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9. K. Tomita, CAMP-ISIJ 8 (1995): 936.
10. G. Agricola, De Re Metallica, 1556 (from 1912 translation, The Mining Magazine, London):
273.
11. R. F. Potocic and K. G. Lewis, Proceedings, McMaster Symposium on External
Desulfurization (1975): paper no. 2.
12. K. D. Haverkamp, Iron and Steel Engineer, (1972): 49; and Proceedings, McMaster
University Symposium (1975), paper no. 14.
13. H. Kajioka, Proceedings, McMaster University Symposium (1975), paper no. 15.
14. N. A. Voronova, Desulfurization of Hot Metal by Magnesium, International Magnesium
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15. W. Mieschner et. al., in Journal of Metals, The Metallurgical Society, 26 (1974): 55; and H.
P. Haastert et. al., McMaster Symposium on External Desulfurization (1975): paper no. 6.
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17. P. J. Koros, U.S. Patent 3,998,625 (1976)
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DeRusha et. al., Steelmaking Proceedings, Iron and Steel Society 73 (1990): 351.
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428
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
22. V. Kendrick et. al., Proceedings, McMaster University Symposium on Hot Metal Preparation
(1983): 13.
23. N. Kurakawa et. al., Technical report, Sumitomo Metal Industries, 45 (1993): 52.
24. A. Aoygi, CAMP-ISIJ 7 (1994): 1080.
25. S. Sasakawa, CAMP-ISIJ 9 (1996): 223.
26. M. Iguchi, CAMP-ISIJ 8 (1995): 106.
27. T. Mitsuo et. al., Trans. Japan Institute of Metals, 23 (1982): 768.
28. H. T. Kossler and P.J. Koros, Steelmaking Proceedings, Iron & Steel Society 67 (1984): 341.
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Proceedings, McMaster Symposium on Developments in Hot Metal Preparation (1983):
310.
32. P. J. Koros, Proceedings, Scaninject III Conference (1983): paper no. 24; and Iron and
Steelmaker, 23 (1983): 23.
33. A. F. Kablukouskij et. al., Metallurg (April 1995): 23.
34. J. Kolsi, Scandinavian J. of Metallurgy 19 (1990): 110.
35. S. K. Srivastava et. al., Proceedings, Scaninject VI Conference, MEFOS (1992): Part II, 73.
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Symposium on Injection in Process Metallurgy, The Metallurgical Society (1991): 81.
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Steelmaker, 23 (1983): 23.
38. R .G. Petrushka, Steelmaking Proceedings, Iron and Steel Society 72 (1989): 167.
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(1987): 325.
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42. Gmelin, Handbook of Inorganic and Organometallic Chemistry, 8th ed. ( New York:
Springer-Verlag, 1992): 135a.
Copyright 1998, The AISE Steel Foundation, Pittsburgh, PA. All rights reserved.
429