Abstract: A method of tapping a steelmaking furnace comprised of determining a desired level of steel to be attained in a ladle, and calculating the weight of molten steel that will be present when the desired level is attained following a transfer of molten steel from the furnace to the ladle. The furnace is operated such that slag is formed on top of molten steel contained therein. The furnace is moved to a first position to cause transfer of molten steel to the ladle to begin. The transfer of molten steel from the furnace to the ladle is continued, and at the first occurrence of molten steel attaining the desired level in the ladle, molten steel attaining a maximum allowable weight in the ladle, or an excessive amount of slag being present upon the molten steel in the ladle, transfer of molten steel to the ladle is ceased.

Abstract: A method of tapping a steelmaking furnace comprised of determining a desired level of steel to be attained in a ladle, and calculating the weight of molten steel that will be present when the desired level is attained following a transfer of molten steel from the furnace to the ladle. The furnace is operated such that slag is formed on top of molten steel contained therein. The furnace is moved to a first position to cause transfer of molten steel to the ladle to begin. The transfer of molten steel from the furnace to the ladle is continued, and at the first occurrence of molten steel attaining the desired level in the ladle, molten steel attaining a maximum allowable weight in the ladle, or an excessive amount of slag being present upon the molten steel in the ladle, transfer of molten steel to the ladle is ceased.

Abstract: A method of making steel in a vessel comprising providing a lance for blowing oxygen on the surface of the steel in the vessel, the lance joined to a lance carriage and in communication with an accelerometer, the accelerometer in signal communication with a data acquisition module and a computer; charging the vessel with materials for steel making; lowering the lance into the vessel and injecting oxygen into the materials; acquiring a signal from the accelerometer indicative of lance vibration; processing the vibration signal to determine component frequencies of lance vibration; comparing the levels of the component frequencies to desired operating values; and adjusting at least one steel making process parameter based on the level of at least one of the component frequencies. The steel making process parameter to be adjusted may be oxygen flow rate through the lance.

Abstract: A slag composition containing steelmaking slag and from about 0.3 to about 10 weight percent of reducing agent. The steelmaking slag contains from about 20 to about 55 weight percent of calcium oxide, from about 8 to about 50 weight percent of ferrous oxide, from about 4 to about 20 weight percent of magnesium oxide, from about 8 to about 30 weight percent of silicon oxide, from 0.5 to about 10 weight per cent aluminum oxide, and from about 0.5 to about 10 weight percent of manganese oxide. The reducing agent contains from about 15 to about 70 weight percent of calcium carbide and from about 10 to about 50 weight percent silicon carbide, wherein the ratio of calcium carbide to silicon carbide is between 0.7 and 7.

Abstract: A method of making steel in a vessel comprising providing a lance for blowing oxygen on the surface of the steel in the vessel, the lance joined to a lance carriage and in communication with an accelerometer, the accelerometer in signal communication with a data acquisition module and a computer; charging the vessel with materials for steel making; lowering the lance into the vessel and injecting oxygen into the materials; acquiring a signal from the accelerometer indicative of lance vibration; processing the vibration signal to determine component frequencies of lance vibration; comparing the levels of the component frequencies to desired operating values; and adjusting at least one steel making process parameter based on the level of at least one of the component frequencies. The steel making process parameter to be adjusted may be oxygen flow rate through the lance.

Abstract: A method of making steel in a vessel comprising providing a lance for blowing oxygen on the surface of the steel in the vessel, the lance joined to a lance carriage and in communication with an accelerometer, the accelerometer in signal communication with a data acquisition module and a computer; charging the vessel with materials for steel making; lowering the lance into the vessel and injecting oxygen into the materials; acquiring a signal from the accelerometer indicative of lance vibration; processing the vibration signal to determine component frequencies of lance vibration; comparing the levels of the component frequencies to desired operating values; and adjusting at least one steel making process parameter based on the level of at least one of the component frequencies. The steel making process parameter to be adjusted may be oxygen flow rate through the lance.

Abstract: A method of making steel in a vessel comprising providing a lance for blowing oxygen on the surface of the steel in the vessel, the lance joined to a lance carriage and in communication with an accelerometer, the accelerometer in signal communication with a data acquisition module and a computer; charging the vessel with materials for steel making; lowering the lance into the vessel and injecting oxygen into the materials; acquiring a signal from the accelerometer indicative of lance vibration; processing the vibration signal to determine component frequencies of lance vibration; comparing the levels of the component frequencies to desired operating values; and adjusting at least one steel making process parameter based on the level of at least one of the component frequencies. The steel making process parameter to be adjusted may be oxygen flow rate through the lance.

Abstract: A method for tapping of steel from a steelmaking furnace to a receiving vessel comprising the steps of providing a steelmaking furnace comprising a tapping hole, and means for angular positioning of the furnace to vary the depth of molten steel and slag contained in the furnace above the tapping hole; determining a guidance profile for the tapping of the furnace, the guidance profile including the parameters of minimum tapping angle, maximum tapping angle, and time of rotation from the minimum tapping angle to the maximum tapping angle; performing an initial angular rotation of the furnace from an initial position to the minimum tapping angle; beginning the transfer of molten steel from the furnace through the tapping hole to a receiving vessel; rotating the furnace to the maximum tapping angle in accordance with the guidance profile; and ceasing the flow of molten steel through the tapping hole.

Abstract: A method of determining disturbances when discharging molten metal from a metallurgical container having an outlet into a receiving container. In steps of this process, a real time video image of the teeming stream is monitored to detect the presence of a slag phase, or conditions conducive to the presence of such a phase in steel being transferred, the monitored images are processed to provide data used to assess the quantity of slag passed, parameters of data generated representing characteristics of the teeming stream image are compared with threshold values to generate at least one signal indicative of the passage of slag, and the threshold values are progressively adjusted responsive to data collected by monitoring plural parameters of the teeming operation selected from predicted teeming duration, weight of the receiving vessel, condition of means controlling teeming rate, and oxygen content of the molten steel.

Abstract: A method of processing molten metal by the injection of oxygen through a water cooled supersonic oxygen injection lance. In the first step of the process, oxygen is injected through the injection lance at an initial flowrate to the process which is the optimal flowrate for the lance tip design. Thereafter, at least one process variable relating to the required oxygen flowrate is continuously measured, and oxygen flowrate may be reduced. A second gas flowrate is admixed to the injection lance to maintain the optimal overall gas flowrate to the process while reducing the oxygen flowrate.

Abstract: A method of determining disturbances when discharging molten metal from a metallurgical container having an outlet into a receiving container. In steps of this process, a real time video image of the teeming stream is monitored to detect the presence of a slag phase, or conditions conducive to the presence of such a phase in steel being transferred, the monitored images are processed to provide data used to assess the quantity of slag passed, parameters of data generated representing characteristics of the teeming stream image are compared with threshold values to generate at least one signal indicative of the passage of slag, and the threshold values are progressively adjusted responsive to data collected by monitoring plural parameters of the teeming operation selected from predicted teeming duration, weight of the receiving vessel, condition of means controlling teeming rate, and oxygen content of the molten steel.

Abstract: A slag composition containing from about 85 to about 99 weight percent of steelmaking slag and from about 1 to about 15 weight percent of a foaming additive. The steelmaking slag is at a temperature of from about 2500 to about 3100 degrees Fahrenheit. The foaming additive contains from about 20 to about 80 weight percent of a source of elemental carbon, from about 5 to about 80 weight percent of calcium carbide, and from about 25 to about 75 weight percent of anoxide compound. The weight ratio of the source of elemental carbon to the calcium carbide is at least 2.

Abstract: A method of determining disturbances when discharging molten metal from a metallurgical container having an outlet into a receiving container. In the first step of this process, one directly or indirectly detects mechanical vibrations caused by the discharge of molten metal through the outlet. Thereafter, a second property is measured; the second property so measured varies during the discharge of molten metal from the first metallurgical container to the receiving container. Then, one calculates a sensitivity constant based upon the measuring of the second property. Thereafter, a comparison is made between the vibrations detected by the measuring device with a desired vibrational characteristic, wherein the desired vibrational characteristic is defined in part by the sensitivity constant; the comparison is analyzed to determine the existence of the disturbances within the outlet, and actions are then taken to cause the disturbance(s) to cease.

Abstract: A method of determining disturbances when discharging molten metal from a metallurgical container having an outlet into a receiving container. In the first step of this process, one directly or indirectly detects mechanical vibrations caused by the discharge of molten metal through the outlet. Thereafter, a second property is measured; the second property so measured varies during the discharge of molten metal from the first metallurgical container to the receiving container. Then, one calculates a sensitivity constant based upon the measuring of the second property. Thereafter, a comparison is made between the vibrations detected by the measuring device with a desired vibrational characteristic, wherein the desired vibrational characteristic is defined in part by the sensitivity constant; the comparison is analyzed to determine the existence of the disturbances within the outlet, and actions are then taken to cause the disturbance(s) to cease.

Abstract: A process of producing magnesium-treated iron such as spheroidal graphite iron (SGI), compacted graphite cast iron (CGI) containing inclusions that deform plastically during machining, said process comprising the steps of: a) producing base iron; b) desulfurizating the base iron produced in step a) with a magnesium free reagent, if it is sulfur concentration exceeds 0.02 % (wt.); c) controlling the oxygen potential and temperature of the base iron to facilitate silicon control of oxygen, if the amount of oxygen exceeds 10 ppm; d) adding aluminum, calcium and/or calcium-containing oxides to the base iron in amounts designed to form dicalcium aluminate deoxidation product or low melting point calcium aluminum silicate deoxidation product; e) treating the base iron with magnesium containing inoculant to attain desired condition for desired nodularity; and f) continuing the process of producing magnesium-treated iron in a per se known manner.

Abstract: Radar is used to measure not only the level of slag on molten steel but also its thickness; the measurement is used to calculate the volume of slag, and, in turn the amount of additives for slag treatment. Time-of-flight data are used to identify peaks representing the distances of the surfaces of the slag and the surface of the underlying steel. The concept is applicable to other materials of differing composition, and particularly where the underlying material is relatively more conductive than the overlying material. Degassing is more efficiently practiced by using the radar slag thickness determinations to assist in vertical placement of snorkels.

Abstract: Radar is used to measure not only the level of slag on molten steel but also its thickness; the measurement is used to calculate the volume of slag, and, in turn the amount of additives for slag treatment. Time-of-flight data are used to identify peaks representing the distances of the surfaces of the slag and the surface of the underlying steel. The concept is applicable to other materials of differing composition, and particularly where the underlying material is relatively more conductive than the overlying material.

Abstract: Radar is used to measure not only the level of slag on molten steel but also its thickness; the measurement is used to calculate the volume of slag, and, in turn the amount of additives for slag treatment.

Abstract: This invention relates to the refining of steel external to a primary steelmaking vessel, for example in the ladle. More particularly, it is: A.) a method of synthesizing a slag on the steel that (i) mitigates the detrimental effects of existing natural slag carried over from the primary steelmaking vessel, (ii) is low in specific bulk density, due to gas evolution and foaming, (iii) is suitable for refining of steel, and (iv) is not aggressive to the ladle refractory lining; B.) a method, and composition for treating any primary slag that has entered the ladle; C.) a method and composition for coating refractory linings. The present invention involves the manufacture in situ of a secondary ladle slag, the treating of ladle slag, and the protection of refractory linings by the addition of materials including calcium carbide, foaming agents such as one or more carbonates of calcium, magnesium, and sodium, and other components used to adjust slag composition.