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Converter steelmaking technology with 40% high scrap ratio via bottom-injected carbon-based thermal compensation: pilot demonstration for industrial decarbonization
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DOI：10.1007/s42243-026-01870-9.png)
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Abstract
En 中文
To overcome the 25%–30% scrap ratio limitation in conventional basic oxygen furnace smelting, a pioneering 500 kg-scale pilot platform was established utilizing bottom-injected carbonaceous materials for high-scrap-ratio smelting. Graphite and sawdust-derived biochar were employed as the carbonaceous materials to provide supplementary heating. Key operational parameters for 25%–40% scrap ratios were determined via a comprehensive mass–energy balance model. Using a batched scrap-charging strategy, stable smelting was achieved at 40% scrap. Comparative analysis demonstrated that graphite offered superior thermal compensation: each kilogram of graphite can melt 7.56 kg of scrap steel, whereas biochar, when used as a heat-supplementing agent, melts an average of 5.16 kg of scrap steel per kilogram. At a 40% scrap ratio, graphite maintained a thermal efficiency of 65%, whereas that of biochar decreased to 48% owing to its high ash content and low fixed-carbon content, inducing slag foaming. Metallurgical indicator improvements included reduced slag oxidation (slag FeO content of 7.8–18.2 wt.% vs. the conventional more than 20 wt.%), a derived quantitative relationship (coefficient of determination, R2 = 0.912), increased metal yield (88%–91%), and minimized hot-metal consumption (659 kg/t). For industrial applications, further work is needed to reduce the cycle length (graphite of 34 min, biochar of 39 min) and endpoint sulfur levels (average of 0.038 wt.%) to reduce the need for secondary refining.
Keywords:
Bottom-injected carbon
High scrap ratio
Metallurgical indicator
Mass–energy balance
Steel industry decarbonization
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