The article presents the results of analyses of numerical modelling of selected factors in electric arc furnace melts. The aim of the study was to optimise the melting process in an electric arc furnace using statistical-thermodynamic modelling based on, among other things, multiple linear regression (MLR). The article presents tools and methods which make it possible to identify the most significant indicators of the process carried out on the analysed unit from the point of view of improvement. The article presents the characteristics of the process and creation of the MLR model and, by applying its numerical analyses and results of calculations and simulations for selected variables and indicator, identifying the operation of a selected furnace. Developed model to demand of electric energy identification was used for calculations of energy balances, the distribution of the energy used in the furnace was presented.

The most up-to-date trends in stainless steel production—aiming at the reduction of production costs—consist of the substitution of steel scrap by hot metal, coming from the reduction of iron-chromium ores. This process requires a more extensive dephosphorization. The dephosphorization process, when applied to chromium steels, requires slag with high dephosphorization properties, as either chromium or chromium oxide entering the slag decreases distinctly the efficiency of the process. The results of laboratory investigations on the dephosphorization of liquid iron solutions containing chromium and nickel are presented. In particular, the study was focused on the selection of the optimal slag composition and the way the slag should be added. The slags based on calcium and fluorite with cryolite additions were considered. It was shown that the variables with the greatest impact on the dephosphorization process include chromium and nickel levels, temperature, and slag basicity. A statistical analysis was performed and regression equations were set. The results may be of use for the design of new methods of production of high-chromium steels.

The article presents the results of numerical simulations of liquid steel flow in the main steelmaking ladle. The paper analyses the mechanism of the outflow of non-metallic Al₂O₃ and MnS inclusions with diameters in the range of 4–27 µm. The simulations were performed with ANSYS Fluent software. In order to determine the shape and size of non-metallic inclusions formed in the main ladle during steel refining, the collected samples of liquid metal were analysed using a scanning microscope with SEM/EDS and LM (light microscopy). Simulation tests and calculations were carried out for the case of steel refining under the conditions of the Cognor SA HSJ Department in Stalowa Wola (Poland). The presented method of using simulation tests to optimize the technology of steel refining in the ladle is an example. The analysis of the results shows that the gas flow in the metal volume has the greatest impact on the outflow of non-metallic inclusions in the steelmaking ladle.

Ferrosilicon (FeSi) is a commercially important material with multiple uses in metallurgical processes. Recently, in an attempt to reduce the carbon impact of the FeSi production process, researchers have proposed using recycled Si recovered from electronic waste in the production of FeSi. However, Si recovered from electronic waste usually contains Al, Cu, and Sn as impurities. Hence, FeSi alloys produced with recycled Si from electronic waste may contain all these elements in varying proportions. Al, Cu, and Sn have been explored as alloying elements to produce alloys with Fe. FeSiAl alloys have also been studied recently for their superior properties. In this work, a multicomponent FeSiAlCuSn alloy is produced, and the phases formed at different temperatures are analyzed using different phase identification techniques. We also analyze the hardness of the multicomponent alloy to find any deviation from the standard FeSi alloy without the additional alloying elements. Understanding the phases and the composition of such alloys may help design future multi-component or high-entropy alloys involving Fe, Si, Al, Cu, and Sn for specific applications.

This paper deals with the subject of high temperature analysis of refining slags originating from a ladle from an actual/industrial secondary refining process. The objective of the conducted research was to learn about the rheological behaviour of the complex industrial slag systems analysed in conditions of variable rheological parameters and temperature, also analyses with a high-temperature microscope. The analysed system seems to be a Newtonian body (with viscosity between 0.1 and 0.8 Pa·s, depend on temperature value, and chemical composition).

The electric arc furnace (EAF) is the initial aggregate and the key point in many carbon steel and in most stainless-steel melting plants. In the article new solutions in construction, technology, operations and control, used in modern steelmaking plant, will be presented. On literature background the results of author’s investigation in electric steelmaking area will be showed. Special attention will be paid on the foaming slag technology used for thermal efficiency increase which means a low cost operation. New elaborated and patented method of stainless-steel slag foaming technology will be described. With slag foaming is connected the optimization procedure concern on minimum the electrical energy consumption and tap-to-tap time. Industrial application in this area will be presented. As a separate chapter the solution in environmental protection during EAF production will be described.