Challenges and opportunities in modeling liquid steel processing using computational thermodynamics – the case of secondary metallurgy
André Luiz Vasconcellos da Costa e Silva
Abstract
The developments in computational thermodynamics (CT) in the last decades have made possible not only the understanding of many aspects of steel behavior during processing and application but also opened the avenue for “Integrated Computational Materials Engineering” which is fast becoming reality. When it comes to the processes that lead to the initial shape and composition of the products, significant advances have also been made on the design of solidification processing, from foundry to continuous and ingot casting as well as additive manufacturing. On the other hand, progress in developing a better understanding of liquid steel processing and of extrapolating this knowledge to design better and more efficient processes has evolved at a relatively slower pace. While most of the thermodynamics needed to understand and control liquid steelmaking operations are well established and consolidated in databases, there is considerable uncertainty on the conditions for mass transfer and their relations to the operational parameters (such as injected gas flow in ladle metallurgy, blow conditions in converter or tapping conditions both in converter and electric furnace) during steelmaking processes and this requires additional investigation and improved sampling. This has led to three main approaches to process control and development: (a) handling of “big data” to derive predictive models (within the bounds of available data) which is extremely useful for process control (b) physico-chemistry based models supported by CT that may be useful for process development and (c) physico-chemistry based models with the use of “big data” for adjustment of some parameters and partially or totally supported by CT which may or may not be useful in process development. In the present paper, we present some recent efforts and results in this area, and highlight the difficulties, limitations and advantages of using models based essentially on physical chemistry fundamentals. We also discuss the possibility of using different approaches, by presenting and comparing selected examples using the three main approaches mentioned above. We try to further the discussion about which would be the more promising approaches both for control and for development of liquid steel processing operations.
Keywords
Referências
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Submetido em:
10/06/2025
Aceito em:
01/07/2025
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