Converter carryover slag and synthetic
slag additions are two elements of the ladle steelmaking system
that can be considered together, as they are the principal
components which go to make up the 'Ladle Top Slag'. The ladle
top slag floats on the surface of the steel in the ladle and
has a profound impact on the inclusion population in the steel.
Converter carryover slag - during primary steel
refining
in the BOS / EAF converter, slag-making additions are made
to form a slag
which absorbs impurities from the steel (such as sulphur
and phosphorus).
During converter tapping, in addition to the crude steel
tapped into the ladle, some converter slag is also carried
over into the steelmaking ladle, hence the name 'carryover
slag'. Since slag contains impurities from primary refining,
it would be very desirable to have zero slag carryover,
as these impurities can revert to the steel in the ladle.
However, some carryover is inevitable. Variable levels of
carryover slag also cause undesirable variation in the ladle
top slag composition, and so it is important to control
both the consistency and level of slag carryover.
Synthetic Slag Additions - form the bulk of the ladle top
slag (normally about 1 tonne). These additions are made
to achieve an aim slag chemistry appropriate to the steel
type being made and its manufacturing process route. Most
synthetic slags are lime
(CaO) based, but a wide range of compositions are employed
to satisfy different metallurgical and operational needs.
Roles of synthetic slag include inclusion engineering, desulphurisation
and heat transfer during ladle re-heating.
The ladle top slag chemically interacts and is in equilibrium
with the steel. In certain steels, the ladle top slag closely
reflects steel inclusion population composition; thus by
manipulating the ladle top slag composition, the inclusion
composition can be controlled to a desirable chemistry. The slag,
which is usually liquid also acts as a capture surface for
inclusions which float out of the steel, and therefore promotes
steel cleaning.
Poor slag control can also lead to poor steel cleanness.
For example, in a steel alloyed
with aluminium
(Al 'killed'), if the ladle top slag is highly oxidised
(high levels of FeO and MnO), then aluminium in the steel
can react with 'oxygen' in the slag to form hard alumina
inclusions in the steel which are detrimental to product
properties.