The invention relates to a liquid feed for a basic oxygen furnace, a method to obtain the liquid feed and a steel plant.

Currently on integrated steelmaking sites the maximum scrap use is about 20 to 25% of the total production volume, although 15 to 20% is more common.

In addition, most integrated sites have restrictions on the use of galvanised scrap, which generally originates from high value steel products. Galvanised steel is widely used for a variety of industrial applications, for example the automotive sector. This product successfully prevents the corrosion of steel. However, the galvanised scrap cannot be utilised in integrated steelmaking sites, as the Zinc (Zn) containing scrap can neither be used in the blast furnace nor in the basic oxygen furnace.

Therefore, the use of scrap, and in particular galvanised scrap, presents a challenge for the circularity of the product.

A well-known process that can handle intake of higher scrap volumes as well as galvanised coated scrap is by melting the scrap in a Scrap Melting Unit (SMU), such as an Electric Arc Furnace (EAF) or Induction Furnace (IF) and turning it directly into new steel. There are no real restrictions on the Zn loading then, and the Zn rich can be used for metallic Zn production via one or two additional processing steps to further concentrate it.

A drawback of this process is the restrictions on the qualities of steel that can be made, one reason is that tramp elements such as Copper(Cu), Chromium (Cr), Nickel (Ni), Molybdenum (Mo) or Tin (Sn) build up in the steel with increased recycling and these cannot be removed in steelmaking. Another reason is that both EAF and IF steelmaking struggle to meet the low nitrogen levels in the steel that can be achieved with (Basic Oxygen Furnace) BOF steelmaking. Hence, high quality steel products, such as pre-consumer scrap, will be processed into a low quality steel product, which cannot be regarded as a sustainable and circular process.

Alternatively, processes are known that convert waste streams into intermediate products. For example, a rotary heart can be used to convert zinc/iron waste streams into a zinc concentrate and direct reduced iron (DRI). Both the DRI and zinc concentrate are intermediate products. The solid DRI can be processed into liquid metal, for example in a blast furnace, steel shop or electric arc furnace.

US2007/0079667A1 , for example, describes a method of producing stainless steel by re-using waste materials as

It is an objective of this invention to provide a liquid feed for high quality steel products and a method to obtain such a liquid feed. The liquid feed and the method to obtain such a liquid feed of the present invention provide a solution to the reuse of scrap, especially galvanised scrap, into high quality steel products while optionally recovering zinc, thereby enabling a sustainable and circular process in an integrated steel plant.

In a first aspect, there is provided a liquid feed for a basic oxygen furnace comprising a first liquid iron stream (1) of carburised molten scrap and a second liquid iron stream(2) from an iron making process. By combining various liquid iron streams, a higher intake of scrap can be realised without compromising on the tramp element requirements or nitrogen inclusions needed for high quality steel products. Furthermore, all liquid iron streams are at the end stage of the iron making processes.

The carburised molten scrap may be obtained from a scrap melting unit such as a EAF or IF. The molten scrap is carburised with carbon, e.g. powdered coal, coke or char coal, such as to obtain a the first liquid iron stream. Preferably, the carbon content of the first liquid iron stream is at least 1 wt.%, more preferably at least 2 wt.%, to ensure a controlled process in the BOF plant. The carbon content should preferably be at most 4 wt.% to ensure an energy efficient process. The molten scrap may be any type of scrap, including galvanised scrap. The inventors realised that by carburising the molten scrap, the oxygen in the scrap is removed, thereby making the scrap into a suitable source for the BOF plant. By carburising the molten scrap a sufficient control of the exothermic process in the BOF plant is ensured. The nitrogen, inherently present in molten scrap, can thus be efficiently removed in the BOF plant and nitrogen inclusions, commonly present in EAF based steels, are hereby prevented.

The second liquid iron stream comes from an iron making process, for example from a blast furnace or a smelting reduction unit (SRU), such as Hlsarna. The second liquid iron stream will typically have low amounts of tramp elements. The Hlsarna ironmaking process is a direct reduced iron process for iron making in which a metalliferous material is processed almost directly into liquid iron. The Hlsarna process and apparatus are described in EP 0726 326 A1, which is hereby incorporated by reference. The metalliferous material is iron ore, optionally supplemented with Hot Briquetted Iron (HBI), Direct reduced iron (DRI) or scrap. The carbon content of the second liquid iron stream is preferably at least 2 wt.% to ensure a controlled process in the BOF plant. Typical carbon contents of the second liquid iron stream are in the range of 3 - 5 wt.%, preferably in the range of 3 - 4 wt.%. Preferably, the second liquid iron stream comes from a smelting reduction unit.

By combining a first liquid iron stream from carburised molten scrap and a second liquid iron stream in a liquid feed for a BOF plant, the level of tramp elements can be controlled by the choice of scrap mix and the ratio between the liquid iron streams. In addition, nitrogen inclusions are prevented in the final steel product by removal of the nitrogen in the BOF plant. Hence the liquid feed according to the invention can be utilized for the production of high quality steel products, while allowing a high intake of scrap.

The liquid iron streams may be combined in a hot metal ladle, optionally pre- processed, e.g. by de-sulphurisation or slag skimming, and can be purified and converted into steel at the BOF plant.

Optionally a third liquid iron stream from an iron making process may be included in the liquid feed. This third liquid iron stream may originate from a blast furnace or a smelting reduction unit.

All the liquid streams are at the end stage of the iron making processes, and are to be combined as the liquid feed for the BOF processes. The liquid feed is processed into steel in the BOF converter. In the BOF scrap, DRI, HBI and/or ore can be added, for example for temperature control. The high quality steel products can be prepared via the conventional techniques as well known in the art.

In an embodiment of the invention, the liquid feed comprises at most 0.04 wt.% Cu and/or at most 0.02 wt.% Sn and/or at most 0.04 wt.% Cr and/or at most 0.04 wt.% Ni and/or at most 0.02 wt.% Mo (all compositional percentages are in weight percent (wt.%) unless otherwise indicated). These tramp elements or residual elements are defined as elements which are not added on purpose to steel and which cannot be removed by simple metallurgical processes. Residual elements enter steel from impurities in ore, coke, flux and scrap; from these, scrap is considered to be the main source of residual elements. By combining at least two liquid iron streams from different sources according to the invention, the amount of tramp elements can be adjusted to the requirements of the end product, while maintaining the possibility to include a significant amount of scrap.

In an embodiment of the invention, the liquid feed comprises at most 0.5 wt.% Silicon (Si), more preferably at most 0.3 wt.% Si, most preferably at most 0.1 wt.% Si. By maintaining a low amount of Si, less heat is generated and the slag formation during steel making is reduced, thereby reducing waste. This can be realised by selecting a second or third liquid iron stream from a smelting reduction unit which typically contains low amounts of Si.

In an embodiment of the invention, the liquid feed comprises at most 0.1 wt.% Phosphorus (P), more preferably at most 0.05 wt.% P, more preferably at most 0.02 wt.% P. By maintaining a low amount of P, new high quality steel products can be accessed. In addition, the slag formation during steel making is reduced, thereby reducing waste. This can be realised, as the liquid iron stream from a smelting reduction unit typically contains low P. In an embodiment of the invention, the liquid feed comprises at least 25 vol.%, preferably at least 30 vol.%, more preferably at least 35 vol.% from the first liquid iron stream and at least 40 vol.%, preferably at least 45 vol.%, more preferably at least 50 vol.% of the second liquid iron stream. By increasing the percentage of the second liquid iron stream, the scrap material used for the first liquid iron stream can have higher impurities, as the second liquid iron stream has a high purity. This allows for a maximum flexibility in scrap selection.

In an embodiment of the invention, the carburised molten scrap of the first liquid iron stream originates from galvanised scrap. A SMU can melt the galvanised scrap while trapping the zinc as zinc oxide in dust. This has the advantage that galvanised scrap can be used in the first liquid iron stream. In contrast with conventional SMU steel making, the carburised molten scrap in the liquid feed for the basic oxygen furnace can be utilised for high quality steel products.

In a second aspect of the invention, there is provided a method to obtain a liquid feed for a basic oxygen furnace comprising the steps of

- Melting scrap in a scrap melting unit,

- Carburizing the molten scrap in the scrap melting unit to obtain a first liquid iron stream,

- Preparing a second liquid iron stream in an ironmaking process,

- Optionally preparing a third liquid iron stream in an ironmaking process,

- Combining the liquid iron streams to obtain the liquid feed for a basic oxygen furnace.

The first liquid iron stream is prepared by melting and carburizing scrap in a scrap melting unit such as a EAF or IF. The scrap is charged in the SMU. The scrap is heated to or above its melting temperature Tmelt, typically between 1400 °C - 1600 °C. The molten scrap may be carburized by blowing a carbon source with a lance in the molten scrap. The carbon source could be powdered coal or char coal. Preferably the scrap is melted at atmospheric pressure. The scrap may be any type of scrap, including galvanised scrap comprising zinc.

In an embodiment the conditions in the scrap melting unit are set to obtain a first liquid iron stream with a carbon content of 1 - 4 wt.%. In conventional processes the molten scrap is not carburised and will typically have a carbon content below 0.5 wt.%. However a carbon content of at least 1 wt.% is desired to make the liquid iron stream suitable for a BOF plant, in order to ensure a controlled process in the BOF plant.

The second liquid iron stream is preferably prepared in a smelting reduction unit, such as Hlsarna. The Hlsarna ironmaking process is a direct reduced iron process for iron making in which a metalliferous material is processed almost directly into liquid iron. The metalliferous material is iron ore, optionally supplemented with HBI, DRI or scrap.

In an embodiment the conditions in the smelting reduction unit are set to obtain a second liquid iron stream with a carbon content of 3 - 4 wt.%.

The first and second liquid iron stream, and optionally a third liquid iron stream are than combined. The conditions and starting materials are chosen as such that the quality of the liquid feed, resulting from the combined liquid iron streams is suitable for the production of high quality steel products. Preferably the liquid feed has a low amount of tramp elements. Preferably the liquid feed comprises at most 0.04 wt.% Cu, at most 0.02 wt.% Sn, at most 0.04 wt.% Cr at most 0.04 wt.% Ni and at most 0.02 wt.% Mo.

The liquid iron streams may be combined in any order. They may be tapped in a container, for example in a hot metal ladle. The combined liquid iron streams should remain liquid, and the overall temperature in the container should preferably be above 1400 °C. In the container, standard operations such as desulphurisation and/or slag skimming may optionally be carried. The combined liquid feed is then charged into the convertor. Optionally the liquid iron streams are combined in the BOF converter.

In an embodiment the liquid feed may be mixed, for example by desulphurisation.

The liquid feed is processed into liquid steel in the BOF. In the BOF scrap/DRI/HBI/ore can be used for temperature control. The high quality steel products can be prepared via the conventional techniques as well known in the art

Overall, a much higher amount of scrap can be processed in the method according to the invention, without compromising the quality of the steel product.

In an embodiment, the first liquid iron stream is prepared by melting and carburizing galvanised scrap in the SMU and the second liquid iron stream is prepared in a smelting reduction unit. The zinc originating from the galvanised scrap is collected as zinc dust, typically comprising about 20 wt.% ZnO. The zinc dust is then injected in the smelting reduction unit, while simultaneously producing the secondary liquid iron stream. To enrich the zinc content in the smelting reduction unit even further, zinc rich iron ores or galvanised scrap can optionally be used in the smelting reduction unit. In the smelting reduction unit the zinc is further concentrated to provide a zinc concentrate, typically comprising at least 60 wt.% ZnO as a valuable by product, such as described in WO2019/185863, which is hereby incorporated in reference. The zinc concentrate can be further processed and used for example for galvanizing steel products. This embodiment of the invention thus recycles the valuable zinc as well as the scrap originating from high quality products into new high quality products and thereby represents a sustainable and circular process for galvanised steel. In a third aspect of the invention, there is provided a steel plant according to claim 15.

A steel plant according to the invention will have the advantage that a much higher amount of scrap can be processed compared to a conventional layout. In addition, a wider variety of scrap quality can be used, for example galvanised scrap. If galvanised scrap is used, the zinc dust is collected in the SMU and injected in the SRU. In the SRU, the zinc dust is concentrated into a zinc concentrate which eventually can be used to galvanise the steel product.

The invention is further explained by the non-limiting example shown in FIG 1. FIG 1 depicts a SMU to provide a first liquid iron stream (1), a SRU to provide a second liquid iron stream (2) and a BF to provide a third liquid iron stream (3). The SMU, is charged with galvanised scrap, melted at about 1500 °C and carburized with powdered coal which is blown in the molten scrap with a lance, such as to obtain the first liquid iron stream with a carbon content of 2.5 wt.%. The SMU further captures the zinc dust, comprising about 15 wt.% of zinc oxide.

Hlsarna is used to provide a second liquid iron stream (2) and is charged with iron ores and coals and 10 wt.% of scrap to create the second liquid iron stream. The zinc dust originating from the SMU is also injected as described in WO2019/185863, thereby obtaining a zinc concentrate comprising more than 40 wt.% of zinc oxide and utilizing all iron further present in the zinc dust.

The blast furnace provides a third liquid iron stream (3) using 0% scrap.

The liquid iron streams are combined to obtain the liquid feed (10) in a ratio of 50 vol% of the first liquid iron stream, 40 vol% of the second liquid iron stream and 10 vol% of the third liquid iron stream, in a container such as a hot metal ladle. The liquid iron streams are consecutively tapped from the source into the ladle. The liquid feed (10) is maintained at a temperature of about 1400 °C. The obtained liquid feed has 0.1 wt.% Si, 0.01 wt.% P, 0.03 wt.% Cu and 0.01 wt.% Sn, thereby allowing for the production of high quality steel products. The liquid feed is de-sulphurised to obtain 0.01 wt.% of S, before charging the liquid feed into the converter at the basic oxygen furnace. The de- sulphurisation also contributes to mixing of the liquid feed. During the primary steel making in the basic oxygen furnace the N is reduced to a level of 10 ppm and a high quality primary steel is obtained. At the basic oxygen furnace 10 wt.% of scrap is added to the converter for temperature control.

As such an overall scrap rate of more than 50 wt.% can be reached in the primary steel making process according to the invention, while allowing for the production of high quality steel products. Depending on the final product and the quality of the scrap, the scrap rate can be increased up to 75 wt.%, if the SMU and Hlsarna are running on maximum scrap rate, thereby contributing to the circular economy.