WORCRA (Continuous) Steelmaking

When designing a manufacturing process, the goal is to cost-effectively produce a high-quality product. In casting, the aim is to generate an optimized process design that can produce a defect-free part as inexpensively as possible. Optimization of process design is an iterative process where an initial design is updated in the light of analysis. A good initial design would reduce the number of cycles in a process optimization. The work described in this article focuses on the development of a computer system that generates an initial design. The main philosophy of this system is based on the observation that a casting process design involves identifying features that are quantified in terms of attributes (e.g., thickness and location). The system operates on these attributes using process design heuristics to arrive at an initial design.

A knowledge-based computer tool for casting process design

The production of carbon steel by the continuous addition of prereduced iron ore to molten auto scrap in an electric furnace appears to have certain operational advantages over conventional cold-melt, batch-charging techniques. Among these are: (1) Lower tramp metal content in the ingot, (2) shorter heat times and lower electrical energy consumption, (3) improved energy input rate during the continuous addition, and (4) flexibility of charge composition by varying ratios of scrap to prereduced iron.

Gerald W. Elger

Papers

Progress report on the use of automobile scrap and directly reduced iron ore in production of electric furnace steel