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Simulation and Techno-Economic Performance of a Novel Charge Calculation and Melt Optimization Planning Model for Steel Making

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Document pages: 24 pages

Abstract: Process algorithm, numerical model and techno-economic assessment ofcharge calculation and furnace bath optimization for target alloy for inductionfurnace-based steelmaking is presented in this study. The developed algorithmcombines the make-to-order (MTO) and charge optimization planning (COP) of thesteel melting shop in the production of target steel composition. Using asystem-level approach, the unit operations involved in the melting process wereanalyzed with the purpose of initial charge calculation, prevailing alloycharge prediction and optimizing the sequence of melt chemistry modification.The model performance was established using real-time production data from acast iron-based foundry with a 1- and 2-ton induction furnace capacity and amedium carbon-based foundry with a 10- and 15-ton induction furnace capacity. Asimulation engine (CastMELT) was developed in Java IDE with a MySQL database for continuousinteraction with changing process parameters to run the model for validation.The comparison between the model prediction and production results was analyzed for charge prediction, melt modificationand ferroalloy optimization and possible cost savings. The model performance for elemental charge prediction and calculation purpose with respect tothe charge input (at overall scrap meltdown) gave R-squared, Standard Error,Pearson correlation and Significance value of (0.934, 0.06, 0.97, 0.0003) forCarbon prediction, (0.962, 0.06, 0.98, 0.00009) for Silicon prediction, (0.999,0.048, 0.999, 9E -11) for Manganese Prediction, and (0.997, 0.076, 0.999, 6E -7) for Chromiumprediction respectively. Correlation analysis for melt modification (aftercharging of ferroalloy) using the model for after-alloying spark analysiscompared with the target chemistry is at 99.82 . The results validate thesuitability of the developed model as a functional system of induction furnacemelting for combined charge calculation and melt optimization Techno-economicevaluation results showed that 0.98 - 0.25 ferroalloy saving per ton of melt is possible using the model. This bringsabout an annual production cost savings of 100,000 $ y in foundry A (mediumcarbon steel) and 20,000 $ y in foundry B (cast iron) on the use of differentferroalloy materials.

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