Introduction of a novel, scrap-based, fully continuous steelmaking process

An attempt to significantly improve meltshop efficiency has led to the development of a new process to melt, refine, alloy, and cast steel, using a system of interconnected vessels. In the proposed process, the steel will be continuously melted in a 55-t Consteel EAF and flow through three refining vessels and a tundish before entering the mold. The reactors and their functions are described and illustrated. The expected chemistry changes, alloying effects, energy requirements, and general operating procedures of the process based on process simulation are presented. Predictions are made about size of the meltshop building, required processing times, possible production rates, and effects of changing operational conditions. Several corrective actions for upset conditions and maintenance issues are described, including the procedures for grade changes.