Basic oxygen furnaces (BOFs) are widely used to produce steel from hot metal. The process typically has limited automation which leads to sub-optimal operation. Economically optimal operation can be potentially achieved by using a dynamic optimization framework to provide operators the best combination of input trajectories. In this paper, a first-principles based dynamic model for the BOF that can be used within the dynamic optimization routine is described. The model extends a previous work by incorporating a model for slag formation and energy balances. In this new version of the mathematical model, the submodel for the decarburization in the emulsion zone is also modified to account for recent findings, and an algebraic equation for the calculation of the calcium oxide saturation in slag is developed. The dynamic model is then used to simulate the operation of two distinct furnaces. It was found that the prediction accuracy of the developed model is significantly superior to its predecessor and the number of process variables that it is able to predict is also higher.

This study focused on the characteristics of complex MnS inclusions in advanced high strength steels. The effect of metal chemistry (Al and N) and the cooling rate of steel were evaluated by analyzing the inclusions present in five laboratory produced steels. The observed complex MnS inclusions contained Al₂O₃-MnS, AlN-MnS, and AlON-MnS. An increase in Al content from 0.5% to 6% increased the number of complex MnS inclusions by ~4 times. In comparison, a decrease of ~80% was observed due to the increased N content of steel from AlON > Al₂O₃. Moreover, it was determined that AlN particles could be easily engulfed at the solidification front relative to Al₂O₃, which resulted in a higher MnS precipitation ratio for Al₂O₃ under slow cooling conditions.

A new approach has been adopted to predict the contribution of the impact and slag-metal bulk zones to the refining rates of impurities in a top blown oxygen steelmaking process. The knowledge pertaining to the behavior of top-jets and bottom stirring plumes (water model and industrial studies) was adapted. For the impact zone, the surface renewal generated by the top jet as well as bottom stirring plumes is incorporated in the current model, whereas in the case of slag-metal bulk zones the surface renewal is caused solely by the bottom stirring plumes. This approach helped in achieving a more explicit use of process parameters in quantifying the slag formation. The results suggest a minor contribution of these two zones to the overall refining of impurities throughout the oxygen blow.

The effect of N content on the characteristics and formation of inclusions in the Fe-5Mn-3Al steels was investigated in this study. Two synthetic steel melts were produced by two different methods—N₂ gas purging and injecting—to introduce nitrogen into the melt. The N content of steel melt varied from 2 to 54 ppm. An increase in the N content to 47 ppm (for 533N-P) and 58 ppm (for 533N-I) increased the total amount of inclusions from 13 to 64 mm⁻² and from 21 to 101 mm⁻², respectively. The observed inclusions were Al₂O_3(pure), Al₂O₃-MnS, AlN_(pure), AlN-MnS, AlON, AlON-MnS, and MnS. When the N content was less than 10 ppm, AlN-MnS inclusions were the primary type of inclusions and they formed as solidification products. With an increase in the N content, AlN_(pure) inclusions became the dominant type of inclusions as AlN was stable in the liquid steel. These findings were confirmed by thermodynamic calculations. The influence of cooling rate on the types of inclusions was studied and a higher number of AlN-MnS inclusions were observed in samples with slow cooling rate.