Transitioning to High Scrap steel Manufacturing

Lead Research Organisation: Swansea University
Department Name: College of Engineering


Key Competitive Driver
The largest technical challenge approaching Tata Steel UK in the next 20 years is to decarbonise product. 80% of CO2 in steel production is generated in the process steps leading up to casting. The current process technology portfolio has overall similarities to others internationally which achieve up to 20% lower carbon emission production than the average at port-talbot due to the incorporation of high proportions of ferrous scrap both in the BF and BOF.
This project aims to add to the body of investigations developing knowledge on the potential of higher ferrous scrap proportion use now, through transition periods and into potential future steel production conditions for the business.
Although aspects such as residual levels will become critical factors in the application of scrap in the production of strip steels, the current control factors which limit scrap usage on a daily basis in PT are:
1. Reaching tapping temperature (1o average gain = £#.##/t/a)
2. Maintaining quality of steel within the BOF - process control such as slag properties and steel cleanness (Al, Si, P and S contamination)
3. Time taken for scrap to melt (Size, shape and packing)
PT is investing in a new scrap pre-heating lance which will enable use of increased scrap volume in the BOF, however this has the potential to have several negative impacts including increased in process time, high levels of scrap oxidation in the vessel, and the formation of intermediate scrap skulls which may impact melting times negatively. With this in mind this project intends to focus on the potential of scrap usage for BOF process stability in order to maximize gain of the heating lance instalment and limit potential negative impacts.

In addition, this specific institute is chosen to deliver the project due to the expertise of identified personal, synergistic activities such as SUSTAIN, I-space, TFI-Demo, SWITCH...etc, the locality of training increasing likely hood to inhouse newly skilled personal and the leverage of funding from EMR to fund a synergistic studentship exploring fundamental questions for the application of scrap in EAF processing.

1. To understand the composition of strategic high volume scrap grades such as heavy basic and incinerator scrap
2. To re-asses the effect of scrap composition on BOF temp after interaction with the pre-treatment lance.
3. Develop understanding for scrap basket mix importance under variable load volumes and with/without pre-heating
4. To inform the steelmaking VIU model as to the better application of scrap grades under new working conditions of pre-heating and high scrap volume use in the steelmaking process.


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Studentship Projects

Project Reference Relationship Related To Start End Student Name
EP/X524827/1 30/09/2022 29/09/2027
2749036 Studentship EP/X524827/1 29/09/2026 29/09/2026 Madeline Bull