📖 ABSTRACT/OVERVIEW
This study applies thermodynamic modelling using FactSage computational thermochemistry software to investigate slag-metal equilibrium conditions in electric arc furnace (EAF) steelmaking as practised at selected Nigerian steel plants in Lagos and Osun States. Accurate thermodynamic modelling of slag-metal partitioning supports the optimisation of slag basicity, oxygen activity, and alloying element recovery, which are critical process control parameters for improving steel quality in Nigerian EAF operations. The FactSage FToxid and FSstel databases are used to calculate phase equilibria and element distribution coefficients between liquid steel and slag as a function of temperature, slag basicity (CaO/SiO2 ratio), and dissolved oxygen activity. Plant operational data including charge compositions, heat temperatures, and final steel and slag chemical analyses from 35 heats are used to validate the thermodynamic predictions. Sensitivity analysis explores the effect of varying MnO, FeO, and Al2O3 slag contents on sulphur and phosphorus partition coefficients. Model predictions are compared with plant measurements. Findings show that dephosphorisation efficiency in the modelled plants is significantly below thermodynamic potential, attributed to insufficient slag basicity (measured CaO/SiO2 averaging 1.8 versus a calculated optimum of 2.8 to 3.0). The study provides a quantitative basis for improving EAF slag practice at Nigerian steel plants. Keywords: thermodynamic modelling, FactSage, slag-metal equilibrium, electric arc furnace, Nigerian steelmaking.
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