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Project Report
On
NITROGEN PICK-UP IN STEEL THROUGH EAF ROUTE
BY
VIVEK KUMAR,
National Institute of Technology, Tiruchirappalli
at
Under the Guidance of:
SANJAY ANAND, AVP
Steel Melting Shop
Jindal Steel and Power Limited
JINDAL STEEL AND POWER LIMITED
RAIGARH-496001, CHHATTISGARH (INDIA)
MAY-JUNE 2014
2
ACKNOWLEDGEMENT
I take this opportunity to express my deep sense of gratitude and regard to Mr. Sanjay Anand,
AVP, Steel Melting Shop, Jindal Steel and Power Limited for his continuous encouragement and
able guidance, I needed to complete this project.
I am indebted to Mr. Sanjeev Kumar, Mr. Vikas Nahar and Mr. Himanshu Biyala, Steel Melting
Shop, Jindal Steel and Power Limited, for their valuable comments and suggestions that have
helped me to make it a success. The valuable and fruitful discussion with them was of immense
help without which it would have been difficult to present this project.
I also wish to thank my family, for providing me help and support whenever required.
Last, but not the least I want to thank the Almighty.
- VIVEK KUMAR
3
ABSTRACT
Steel making through electric arc furnace (EAF) is one of the most popular and versatile steel making
practices followed all over the world. In recent years, there has been a substantial increase in production
of steel making via EAF route. Superior quality with low cost has become a yard stick for the steel
manufacturers to meet the customer’s demand. The challenges are to produce steel with low residuals and
low gaseous elements to serve the critical quality sensitive steel markets like automobile, API line pipe,
Boiler and ship building.
Absorption of nitrogen during steel making results in interstitial solid solution strengthening and grain
refinement due to the formation of nitrides, both the factors increase the hardness of the steel. Presence of
high nitrogen content may result in inconsistent mechanical properties in hot rolled products of steel,
embrittlement of the heat affected zone (HAZ) of welded steels, and poor cold formability, reducing the
ductility of cold rolled and annealed low carbon aluminum killed steel. The work describes in detail the
factors responsible for the nitrogen pick-up in steel produced through EAF operations along with tapping
variations.
4
TABLE OF CONTENTS
1. INTRODUCTION
2. EFFECTS OF NITROGEN IN THE STEEL
3. IMPACT OF VARIOUS ELECTRIC ARC FURNACE PARAMETERS ON NITROGEN
3.1 CHARGE MIX
3.2 HOT METAL
3.3 DRI LUMPS
3.4 BUCKET CHARGE & DRI FINES
3.5 OPERATIONS
4. NITROGEN PICK-UP DURING TAPPING
5. CONCLUSIONS
6. REFERENCES
5
1. INTRODUCTION
The presence of nitrogen, hydrogen and oxygen are inevitable components in all commercial steels.
Nitrogen can be considered as an impurity or a desired alloying addition. Stainless steel consists of 18%
Cr and 8% Ni. But to reduce the cost, nitrogen content is increased to a desired level to compensate Ni.
Though nitrogen is lost due to aging and causes cracking, this steel is popular for use-and-throw
materials. However, in the case of carbon and low alloy steels the nitrogen content needed to be restricted
since the same is not desired. Nitrogen even in small quantities is detrimental to the quality of steel and, it
is difficult to remove. This is because high level of nitrogen results in inconsistent mechanical properties
in hot-rolled products, yield to embrittlement of the heat affected zone (HAZ) of welded steels, and poor
cold formability. In particular, nitrogen can result in strain ageing and reduced ductility of cold-rolled and
annealed steels. The objective of this work is to study the nitrogen pick-up occurring in steels produced
through EAF-LRF-Caster route. There are numerous sources through which nitrogen enters steel and
stays in the form of solution when steel is in molten state. The main source of nitrogen in steel is from
charge material which includes hot metal, scrap, DRI lumps and fines, nitrogen impurity in oxygen used
for steel making, lime and coke. Nitrogen pickup from the atmosphere can occur during oxygen re-blows
in which case the furnace fills up with air, which is then entrained into the metal if the slag layer is absent
over the liquid steel when the oxygen blow restarts. During the tapping of steel, the air bubbles are
entrained into the steel where the tap stream enters the bath in the ladle which results in nitrogen pick-up.
The metal bath in the ladle is mildly purged with argon due to which the metal bath comes in contact with
the atmosphere due to which nitrogen content of steel increases in absence of slag layer over the metal.
Other sources of nitrogen are coke (as carburizers) and various ferroalloys added for alloy steels. On
solidification, the nitrogen present in steel forms nitrides with other alloying elements such as Ti, Al, V,
etc. present in steel. The presence of significant quantities of other elements in liquid iron affects the
solubility of nitrogen. The presence of dissolved sulphur and oxygen limit the absorption of nitrogen
because they are surface-active elements. The work basically aims to study nitrogen pick-up in Electric
Arc Furnace during operation and tapping by considering the variation of charge mix and carbon content
respectively. The data is collected from Jindal Steel and Power Limited (JSPL), Raigarh.
6
2. EFFECTS OF NITROGEN IN THE STEEL
When nitrogen is added to austenitic steels, it improves fatigue life, strength, wear and localized corrosion
resistance, work hardening rate. However, the presence of nitrogen in carbon or low alloy steels is not
desirable.
When liquid steel solidifies the nitrogen present in it forms stable nitrides with the alloying elements of
the steel such as Al, Si, Cr. The dissolved nitrogen affects the toughness and ageing characteristics of
steel as well as enhancing the tendency towards stress corrosion cracking. Its strain hardening effect does
not allow extensive cold working without intermittent annealing and hence low nitrogen is essential for
deep drawing of steel limiting the nitrogen in the steel to 60ppm.
Presence of high nitrogen content may result in inconsistent mechanical properties in hot rolled products
of steel, embrittlement of the heat affected zone (HAZ) of welded steels, and poor cold formability,
reducing the ductility of cold rolled and annealed low carbon aluminium killed steel.
Nitrogen itself in pure carbon steel increases the hardenability of the steel but in presence of nitride
forming alloying elements it can decrease the hardenability because nitrogen combine with these alloying
elements and thus decreasing their potential as hardenability agents.[effect of nitrogen and vanadium on hardenability—H
Adrian]
Absorption of nitrogen during steel making results in interstitial solid solution strengthening and grain
refinement due to the formation of nitrides, both the factors increase the hardness of the steel. This idea is
used to develop a specialized technique of heat treatment called case hardening where the surface of the
component is preferentially enriched with Nitrogen gas to increase its surface hardness while retaining a
soft core.
Fig.1 Effect of nitrogen on yield strength, tensile strength, r-value and elongation of steel in the annealed
condition
7
The fig.1 shows that with the increase in the nitrogen content of the steel the strength value decreases
initially and then shoots up resulting in the decrease of elongation, r-value, which is a measure of thermal
resistance. Hence, high nitrogen content leads to poor formability of steels.
The appearance of strain ageing in the steel is attributed to the presence of the interstitial elements like
nitrogen and carbon after they have been plastically deformed followed by the segregation of the nitrogen
to the dislocations causing discontinuous yielding on further deformation and is characterized by the
presence of stretcher strains which results in increased hardness and strength at the cost of reduced
ductility and toughness.
The presence of free nitrogen in the steel increases the ductile to brittle transition temperature thereby
decreasing its toughness which is attributed to solid solution strengthening. Further, the presence of
limited amount of nitrogen in the steel forms nitride with strong nitride forming elements like aluminium,
vanadium, titanium and niobium resulting in the formation of fine grained ferrite which in turn lowers the
transition temperature thus improving its toughness.
Fig.2 Effect of free nitrogen on impact properties
During welding the nitrides present in the HAZ are dissociated as a result of high temperature that exists
during welding leading to loss of the toughness of the HAZ and is referred as HAZ embrittlement .
Further the absence of the precipitates results in the formation of coarse grains in the HAZ [1].
In certain HSLA grades of steel the requirement of nitrogen extends to 0.02% to obtain high strength but
this is accompanied by a drop in the notch toughness. The production of cold rolled sheets through the
continuous annealing process demands a nitrogen level of 25-40 ppm.[NITK suratkal]s
8
3. IMPACT OF VARIOUS ELECTRIC ARC FURNACE PARAMETERS ON
NITROGEN
3.1. CHARGE MIX
The main source of nitrogen is the charge mix involved during steel making. To get an impression of the
sources of nitrogen during the melting process, the amount of nitrogen present in each of the feed
materials typically used in the EAF is shown in Table 1.
Table 1: Nitrogen content of feed materials used in EAF steelmaking at JSPL, Raigarh [9]
FEED MATERIAL NITROGEN CONTENT
Scrap 60-100 ppm
HBI 20-30 ppm
DRI 60-80 ppm
Liquid iron from Blast Furnace 60 ppm
CPC 5000-10000 ppm
Oxygen 30-200 ppm
Lime (CaO) 400 ppm
The charge-mix of heats analyzed was used to calculate the theoretical nitrogen content that would prevail
in the bath from simple mass balance equations.
Table 2: Chemical composition of HBI and DRI in JSPL, Raigarh [9]
CHEMICALANALYSIS (%) HBI DRI
Total Iron 91.95 88.2
Metallic Iron 83.12 79.5
Metallization 90.4 90.1
FeO 11.35 11.2
Carbon 1.33 0.07
SiO2 2.93 5.7
Al2O3 1.24 2.1
Sulphur 0.008 0.02
Phosphorous 0.053 0.07
Nitrogen (in ppm) <30 60-80
9
Fig.3 Influence of charge-mix on the nitrogen content (in ppm) in the bath (Source: JSPL, Raigarh)
From fig.3 the nitrogen content in the bath just before tap is always less than the theoretical nitrogen
content obtained when calculated from the charge-mix. Although coke plays an important role in
increasing the nitrogen content, but by what factor is not clear yet. The coke is injected in the bath and
above the slag layer via. carbojets to increase the foaminess of the slag. The carbon from coke reacts with
FeO present in the slag to form CO gas bubbles which rush out from the molten bath thus increasing the
foaminess of the slag. The slag should be foamy because it helps in covering the arc originating from the
electrodes. Also, it helps in continuous removal of impurities from the steel by continuously circulating
the slag and thus forming a new slag-metal interface. This conditioning is very useful to obtain cleaner
steel but at the same time the slag is continuously drained out from the slag door. The removal of slag is
important to avoid rephosphorization from the slag layer into the metal bath. So, the conditioning and
removal of slag are simultaneously maintained by the presence of foaminess in the slag. Thus, coke
injection is important and cannot be avoided in Electric Arc Furnace operation. So to have an upper and
lower limit of nitrogen theoretically present, there are two curves plotted, one taking nitrogen from coke
into account while another completely ruling out the possibility of the same respectively. As coke
injection cannot be avoided in Electric Arc Furnace operation, the amount of nitrogen theoretically
present lies in the above mentioned range.
0
20
40
60
80
100
120
140
160
0 10 20 30 40 50 60
NitrogenContent(inppm)
Heat No.
Practical N before tap
Theoretical N considering
pick-up from coke
Theoretical N without
considering N pick-up from
coke
Linear (Practical N before
tap)
Linear (Theoretical N
considering pick-up from
coke)
Linear (Theoretical N without
considering N pick-up from
coke)
10
The metallic materials charged in EAF are hot metal from Blast furnace, MS scrap, skull and DRI lumps
and fines. The charge-mix does play an important role in determining the nitrogen content in the steel
bath.
3.2. HOT METAL
The hot metal from blast furnace contains about 55-65 ppm of nitrogen in it. During tapping, the Electric
Arc furnace is never completely emptied and contains liquid steel of previous heat tapped on an average
of 20-30 % of furnace capacity in it termed as Hot Heel. The hot heel present contains high oxygen
content along with oxidizing slag layer above it. So, when the hot metal (rich in C-content) is being
charged, it comes in contact with the oxygen present in the hot heel thus getting oxidized to form CO
bubbles in the initial stage. The CO gas produced flushes out nitrogen out of the metal bath and also
creates a protective atmosphere over the melt that reduces the nitrogen pick-up from the atmosphere. So,
the formation of protective layer in the initial stage of arcing prevents pick-up from the atmosphere.
Fig.4 Influence of Hot Metal content in metallic charge on the tap Nitrogen content (Source JSPL,
Raigarh)
3.3. DRI LUMPS
The plot as shown in fig.5 is variation of nitrogen content with coal-based DRI lumps that are charged
from the top with the help of a chute in the furnace.
0
10
20
30
40
50
60
70
30 40 50 60 70
NitrogenContent(inppm)
Hot Metal in metallic charge (%)
11
Fig.5 Influence of DRI lumps content in metallic charge on the tap Nitrogen content (Source JSPL,
Raigarh)
The increased use of DRI lumps shows an increase in the nitrogen content in the bath (fig.5). The DRI
used is coal-based DRI which has high nitrogen content in it. The DRI is continuously charged from the
top with the help of the chute to increase the metallic content and also acts as a coolant. Due to
continuous charging, the melting of DRI takes longer time and it occurs till the end of the arcing
operation. This leads to lesser formation of CO bubbles and results in retention of nitrogen from DRI
lumps in the steel bath. Careful and increased oxygen blowing and carbon injection to produce CO gas
bubbles during the end of the arcing process can lead to removal of nitrogen but is time, material and
energy wastage which is avoided in plant practice for economic reasons if not required for making special
grade steels.
3.4. BUCKET CHARGE AND DRI FINES
The bucket charge contains MS scrap; skull from the slag pot, tundish, etc. and DRI fines. Sometimes,
Hot Briquetted Iron (HBI) is also charged through top charging depending upon its availability. The use
of bucket charge and DRI fines gives lower nitrogen content in the bath and at the same time is cost
effective. But the use of bucket requires a higher arcing time and higher energy as compared to that of hot
metal.
0
10
20
30
40
50
60
70
20 30 40 50 60
NitrogenContent(inppm)
DRI lumps in metallic charge (in %)
12
Fig 6. Influence of Bucket charge on the tap Nitrogen content (Source JSPL, Raigarh)
Fig 7. Influence of DRI fines in metallic charge on the tap Nitrogen content (Source JSPL, Raigarh)
The increased use of bucket and DRI fines in the charge mix has shown a decrease in the nitrogen
content. The decrease is undoubtedly attributed to CO gas bubbles formation in the initial stage. The rate
of formation is fast due smaller size and requires lesser time for melting. But the mechanism of CO
formation is different as compared to that of hot metal. The addition of DRI fines, iron carbide in the form
of skull and scrap contains iron oxides either unreduced or in the form of corrosion product respectively
that serve as a source of oxygen for the formation of CO by an “internal” decarburization reaction,
namely:
O(DRI) + C(DRI-Fe)  CO(g) ……..(1)
y = -0.0493x + 55.634
0
10
20
30
40
50
60
70
0 5 10 15 20
NitrogenContent(inppm)
Bucket Charge (in %)
y = -0.0526x + 55.438
0
10
20
30
40
50
60
70
0 5 10 15
NitrogenContent(inppm)
DRI fines in Metallic Charge (in %)
13
Thermogravimetric studies of DRI fines and iron carbide have shown that “internal decarburization”
commences above 800 0
C, possibly due to physical changes inside the DRI particles [2]. The decrease in
nitrogen content observed (fig5. & fig6. ) is not significant due to two reasons. The first reason is
buoyancy. Goldstein et al. in their work concluded that the nitrogen removal effect of CO bubbling from
the decarburization reaction in DRI are largely lost in steelmaking operations because the bubbles are
generated high in the melt as a result of the buoyancy of DRI pellets[3]. The same argument can be
extended to the use of DRI fines and bucket charge which are charged in the furnace by top charging in
the initial stage. Thus they remain on the higher side in the melt thereby reducing the nitrogen removal
effect by CO bubbling. Though it is advantageous to have increased DRI fines content in the charge-mix
from nitrogen point of view, but this is an undesirable practice if charging is done from the top. The fines
been lighter in weight get blown away by the Fumes Extraction System (FES). So, this leads to reduction
in the metallic yield and wastage of the DRI fines. So to have both lower nitrogen content and higher
metallic yield, DRI fine injection should be carried out deep in the bath with the help of lance so that fines
get a higher time to react thus resulting in efficient removal of nitrogen content. There are few models
such as Jet Penetration Model which is in use in some of the plants like Mittal Steel Hamburg for many
years which has been injecting DRI fines into the EAF at rates of approximately 1 Tonne min-1
.[2] The
second reason is the low C-content in the coal-based DRI. The carbon content in coal-based DRI is
around 0.07% (table 2.) which is very low as compared to gas-based DRI. Thus, CO gas evolved is quite
low (1) which results in reduced level of nitrogen flushing from the steel bath.
There is a decrease in nitrogen content observed (from fig4, fig6 and fig7) by use of hot metal, bucket
charge which contains scrap, skull and DRI fines in varying amount depending upon the availability. This
decrease in the nitrogen content can be attributed to formation of CO gas bubbles. It is well established
that CO bubbles passing through a steel melt have a scrubbing effect on dissolved nitrogen, as nitrogen is
readily absorbed into CO bubbles [2]. There has also been a study by Goldstein et al. that addition of DRI
pellets helps to remove nitrogen from steel, and has quantified the fundamental kinetics of nitrogen
removal by CO bubbling. [3]
3.5. OPERATIONS
In Electric Arc Furnace, the process of decarburization and dephosphorization is carried out to produce
steel of desired chemical composition and mechanical properties.
14
Fig 8. Solubility of nitrogen in iron for temperatures of 600-2000°C [4]
Phosphorus removal reaction is given by [5]
2 [P] + 5 [O] = (P2O5) ……….(2)
∆ G° = −740375+ 535.365T J/mol ……….(3)
∆ G° becomes positive at T > 1382K which results in decomposition of P2O5 to P and O. Thus removal of
phosphrous requires that a(P2O5) must be reduced.
KP = a(P2O5) / [wt% P]2
[wt% O]5
.………(4)
But,
∆ G° = -2.303RT log(Kp) ……….(5)
Therefore, from equation (3) and (5), we have
Log Kp = (38668/T) – 27.96 ………(6)
The equation (6) shows that lower the value of temperature, higher is the Kp which means higher and
effective dephosphorization of the steel bath under identical conditions of slag basicity and oxidizing
potential.
From nitrogen point of view, the pick-up is not possible in the EAF if process is carried out for
dephosphorization where temperature is maintained around 1500-1550 0
C in which the solubility of
15
nitrogen is around 5-15 ppm (fig. 8). But, before tapping during the end, the temperature is raised to
around 1600-1630 0
C which increases the chances of nitrogen pick-up as the solubility in this range is
around 45-50 ppm (fig 8.) if the steel bath in the furnace comes in contact with the atmosphere. This
occurs if the slag layer above the steel bath is drained out by the furnace operator before tapping thereby
increasing the air ingression tendency from the slag door. Also, absence of slag layer results in bare-
arcing due to which nitrogen from the atmosphere dissociates in ionic form which has a higher probability
to dissolve in the steel bath. This results in pick-up of nitrogen.
16
4. NITROGEN PICK-UP DURING TAPPING
During tapping, the liquid steel flows out in the form of stream which is in continuous contact with the
atmosphere until the ladle is filled. The main source of nitrogen pick-up is from the atmosphere when
liquid steel is tapped from the furnace at around 1600 0
C. Nitrogen being a diatomic gas follows Sievert’s
law which states that solubility of a diatomic gas in a liquid is directly proportional to the square-root of
its partial pressure.
The main reaction for absorption of nitrogen into steel bath following Sievert’s law is given as:
0.5 N2  [N] …..(7)
The equilibrium constant for equation (7) is well established to be 0.045 wt. % x atm-1/2
at 16000
C, or in
other words at one atmosphere of pure nitrogen pressure, 450 ppm [N] dissolves in pure iron at 16000
C
.In the case of pure Fe-C alloys, the plot (fig 9.) shows that with decreasing carbon content in iron carbon
alloy, the nitrogen solubility increases. [6]
Fig 9. Solubilities of hydrogen and nitrogen (at 1.0 atm) in iron-carbon alloys at 1600°C. [6]
17
In the case of steel tapped from the EAF, it contains various other alloying elements such as Mn, Si, S, O,
P, Al, etc depending upon the charge-mix along with furnace operation conditions. The nitrogen pick-up
which occurs during tapping can be controlled if the tapping duration is reduced or by some chemistry
alterations. Alloying elements such as O and S acts as impurities but are very useful in controlling
nitrogen pick-up from the atmosphere during tapping.
O and S are surface active elements which gather on the molten steel surface thereby resisting the reaction
(7)[8]. This means that both forward and backward reactions are hampered with increase in O and S
content. So, the nitrogen present in the steel in the EAF process before tapping remains more or less same
after the tapping is over if the O and S content is high i.e. forward reaction is retarded.
To establish the above fact, the variation of nitrogen pick-up with C-content is studied. The data of heats
analyzed is plotted for C-content with the nitrogen pick-up during tapping.
Fig 10. Influence of C-content in the bath on the nitrogen pick-up during tapping (Source: JSPL Raigarh)
There is a hyperbolic relationship between amount of carbon (wt%) in the bath to that of dissolved
oxygen (wt%) in the bath (fig 9). The constant depends upon the temperature as well as the partial
pressure of CO in the bath.[5]
R² = 0.4771
0
2
4
6
8
10
12
14
16
18
20
0 0.05 0.1 0.15 0.2
Nitrogenpick-up(inppm)
C-content in the bath (wt%)
18
Fig 11. Equilibrium [C] and [O] concentrations at different pressures [7]
The relationship between dissolved carbon and dissolved oxygen in the molten steel bath at 16000
C of in
equilibrium with pco= 1 atm is given as [5]
[wt%C] [wt%O] = 0.0024 ….(8)
Equation (8) shows that on increasing C-content leads to decrease in the dissolved oxygen in the bath.
Also, the plot (fig 10.) shows that with increasing carbon content, the nitrogen pick-up during tapping
increases. So, the relation is well established that presence of higher oxygen in the bath will lead to lesser
nitrogen pick-up in the steel.
The aluminum addition during tapping is done which reduces the oxygen content in steel due to formation
of alumina (Al2O3). So, the carbon initially present in the steel and also which is added as an additive
during tapping can now only react with left-over oxygen in the bath due to which there is reduced
formation of CO thereby reducing the flushing capacity of nitrogen from the bath.
So, the reduced flushing capacity and reduced O content in the bath are both responsible for higher
nitrogen pick-up during tapping. It must be noted that these variations studied are done by keeping the
sulphur content in the steel constant. The effect of sulphur on the pick-up is not established due to
shortage of data.
19
5. CONCLUSION
Due to the increasing production of flat products and other high end steel products via the EAF
steelmaking route, the requirement for strict nitrogen control is becoming ever greater. The pick-up in the
EAF is not signification during operations under proper foamy slag practice. The main source is the
charge-mix in which focus should be made of increased use of hot metal or DRI fines to flush out the
nitrogen by generating a slag early in the melting stage in order to shield the metal from the atmosphere;
helping generate a foamy slag; and producing a CO boil within the steel bath. To obtain better results,
DRI fines rich in C-content should be used and should be injected deep in the bath.
The pick-up during tapping is a function of chemistry and temperature of the liquid steel when tapped in
open atmospheric contact. The presence of surface active elements like Oxygen and Sulphur retard the
pick-up of nitrogen from atmosphere in steel. Also, the killing practice should be carried out in such a
way that the carbon in the bath is allowed to react with excess oxygen producing CO to flush out the
nitrogen and at the same time form a protective layer over the steel bath to avoid further pick-up.
20
6. REFERENCES
1. P R Sureshkumar, D R Pawar, V Krishnamoorthy, How to make N2 listen to you in steel
making!, International Journal of Scientific & Engineering Research Volume 2, Issue 10,
October-2011, ISSN 2229-5518, pp. 1-5
2. Dorel Anghelina, Gordon A. Irons, Geoffrey A. Brooks, Nitrogen Removal from Steel by DRI
Fines Injection, AISTech 2005 Proceedings - Volume I, pp. 403-409
3. D. A. Goldstein, R. J. Fruehan, Mathematical model for nitrogen control in oxygen steelmaking,
Metallurgical and Materials Transactions B, October 1999, Volume 30, Issue 5, pp. 945-956
4. www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=202
5. Amit chaterjee and A Ghosh
6. Siddhartha Misra, Yun Li, Il Sohn, Hydrogen and Nitrogen Control in Steelmaking at U. S. Steel,
Association for Iron and Steel Technologies
7. Electric Arc Furnace Simulation User Guide ,Version 1, steeluniversity.org
8. Jie Fu, Shixiang Zhou, Ping Wang, Lin Di, Jian Zhu, Effects of Temperature and [S] on the
kinetics of Nitrogen Removal from Liquid Steel, J. Material Science Technology, Volume:7
No.2,2001,pp 233-236.
9. Ashutosh Sharma, Joy Dutta, Amit Khokhar, Sanjay Anand, B. Lakshminarasimham, Nitrogen
Control during EAF Steelmaking at Jindal Steel & Power Limited,

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JSPL Report

  • 1. 1 Project Report On NITROGEN PICK-UP IN STEEL THROUGH EAF ROUTE BY VIVEK KUMAR, National Institute of Technology, Tiruchirappalli at Under the Guidance of: SANJAY ANAND, AVP Steel Melting Shop Jindal Steel and Power Limited JINDAL STEEL AND POWER LIMITED RAIGARH-496001, CHHATTISGARH (INDIA) MAY-JUNE 2014
  • 2. 2 ACKNOWLEDGEMENT I take this opportunity to express my deep sense of gratitude and regard to Mr. Sanjay Anand, AVP, Steel Melting Shop, Jindal Steel and Power Limited for his continuous encouragement and able guidance, I needed to complete this project. I am indebted to Mr. Sanjeev Kumar, Mr. Vikas Nahar and Mr. Himanshu Biyala, Steel Melting Shop, Jindal Steel and Power Limited, for their valuable comments and suggestions that have helped me to make it a success. The valuable and fruitful discussion with them was of immense help without which it would have been difficult to present this project. I also wish to thank my family, for providing me help and support whenever required. Last, but not the least I want to thank the Almighty. - VIVEK KUMAR
  • 3. 3 ABSTRACT Steel making through electric arc furnace (EAF) is one of the most popular and versatile steel making practices followed all over the world. In recent years, there has been a substantial increase in production of steel making via EAF route. Superior quality with low cost has become a yard stick for the steel manufacturers to meet the customer’s demand. The challenges are to produce steel with low residuals and low gaseous elements to serve the critical quality sensitive steel markets like automobile, API line pipe, Boiler and ship building. Absorption of nitrogen during steel making results in interstitial solid solution strengthening and grain refinement due to the formation of nitrides, both the factors increase the hardness of the steel. Presence of high nitrogen content may result in inconsistent mechanical properties in hot rolled products of steel, embrittlement of the heat affected zone (HAZ) of welded steels, and poor cold formability, reducing the ductility of cold rolled and annealed low carbon aluminum killed steel. The work describes in detail the factors responsible for the nitrogen pick-up in steel produced through EAF operations along with tapping variations.
  • 4. 4 TABLE OF CONTENTS 1. INTRODUCTION 2. EFFECTS OF NITROGEN IN THE STEEL 3. IMPACT OF VARIOUS ELECTRIC ARC FURNACE PARAMETERS ON NITROGEN 3.1 CHARGE MIX 3.2 HOT METAL 3.3 DRI LUMPS 3.4 BUCKET CHARGE & DRI FINES 3.5 OPERATIONS 4. NITROGEN PICK-UP DURING TAPPING 5. CONCLUSIONS 6. REFERENCES
  • 5. 5 1. INTRODUCTION The presence of nitrogen, hydrogen and oxygen are inevitable components in all commercial steels. Nitrogen can be considered as an impurity or a desired alloying addition. Stainless steel consists of 18% Cr and 8% Ni. But to reduce the cost, nitrogen content is increased to a desired level to compensate Ni. Though nitrogen is lost due to aging and causes cracking, this steel is popular for use-and-throw materials. However, in the case of carbon and low alloy steels the nitrogen content needed to be restricted since the same is not desired. Nitrogen even in small quantities is detrimental to the quality of steel and, it is difficult to remove. This is because high level of nitrogen results in inconsistent mechanical properties in hot-rolled products, yield to embrittlement of the heat affected zone (HAZ) of welded steels, and poor cold formability. In particular, nitrogen can result in strain ageing and reduced ductility of cold-rolled and annealed steels. The objective of this work is to study the nitrogen pick-up occurring in steels produced through EAF-LRF-Caster route. There are numerous sources through which nitrogen enters steel and stays in the form of solution when steel is in molten state. The main source of nitrogen in steel is from charge material which includes hot metal, scrap, DRI lumps and fines, nitrogen impurity in oxygen used for steel making, lime and coke. Nitrogen pickup from the atmosphere can occur during oxygen re-blows in which case the furnace fills up with air, which is then entrained into the metal if the slag layer is absent over the liquid steel when the oxygen blow restarts. During the tapping of steel, the air bubbles are entrained into the steel where the tap stream enters the bath in the ladle which results in nitrogen pick-up. The metal bath in the ladle is mildly purged with argon due to which the metal bath comes in contact with the atmosphere due to which nitrogen content of steel increases in absence of slag layer over the metal. Other sources of nitrogen are coke (as carburizers) and various ferroalloys added for alloy steels. On solidification, the nitrogen present in steel forms nitrides with other alloying elements such as Ti, Al, V, etc. present in steel. The presence of significant quantities of other elements in liquid iron affects the solubility of nitrogen. The presence of dissolved sulphur and oxygen limit the absorption of nitrogen because they are surface-active elements. The work basically aims to study nitrogen pick-up in Electric Arc Furnace during operation and tapping by considering the variation of charge mix and carbon content respectively. The data is collected from Jindal Steel and Power Limited (JSPL), Raigarh.
  • 6. 6 2. EFFECTS OF NITROGEN IN THE STEEL When nitrogen is added to austenitic steels, it improves fatigue life, strength, wear and localized corrosion resistance, work hardening rate. However, the presence of nitrogen in carbon or low alloy steels is not desirable. When liquid steel solidifies the nitrogen present in it forms stable nitrides with the alloying elements of the steel such as Al, Si, Cr. The dissolved nitrogen affects the toughness and ageing characteristics of steel as well as enhancing the tendency towards stress corrosion cracking. Its strain hardening effect does not allow extensive cold working without intermittent annealing and hence low nitrogen is essential for deep drawing of steel limiting the nitrogen in the steel to 60ppm. Presence of high nitrogen content may result in inconsistent mechanical properties in hot rolled products of steel, embrittlement of the heat affected zone (HAZ) of welded steels, and poor cold formability, reducing the ductility of cold rolled and annealed low carbon aluminium killed steel. Nitrogen itself in pure carbon steel increases the hardenability of the steel but in presence of nitride forming alloying elements it can decrease the hardenability because nitrogen combine with these alloying elements and thus decreasing their potential as hardenability agents.[effect of nitrogen and vanadium on hardenability—H Adrian] Absorption of nitrogen during steel making results in interstitial solid solution strengthening and grain refinement due to the formation of nitrides, both the factors increase the hardness of the steel. This idea is used to develop a specialized technique of heat treatment called case hardening where the surface of the component is preferentially enriched with Nitrogen gas to increase its surface hardness while retaining a soft core. Fig.1 Effect of nitrogen on yield strength, tensile strength, r-value and elongation of steel in the annealed condition
  • 7. 7 The fig.1 shows that with the increase in the nitrogen content of the steel the strength value decreases initially and then shoots up resulting in the decrease of elongation, r-value, which is a measure of thermal resistance. Hence, high nitrogen content leads to poor formability of steels. The appearance of strain ageing in the steel is attributed to the presence of the interstitial elements like nitrogen and carbon after they have been plastically deformed followed by the segregation of the nitrogen to the dislocations causing discontinuous yielding on further deformation and is characterized by the presence of stretcher strains which results in increased hardness and strength at the cost of reduced ductility and toughness. The presence of free nitrogen in the steel increases the ductile to brittle transition temperature thereby decreasing its toughness which is attributed to solid solution strengthening. Further, the presence of limited amount of nitrogen in the steel forms nitride with strong nitride forming elements like aluminium, vanadium, titanium and niobium resulting in the formation of fine grained ferrite which in turn lowers the transition temperature thus improving its toughness. Fig.2 Effect of free nitrogen on impact properties During welding the nitrides present in the HAZ are dissociated as a result of high temperature that exists during welding leading to loss of the toughness of the HAZ and is referred as HAZ embrittlement . Further the absence of the precipitates results in the formation of coarse grains in the HAZ [1]. In certain HSLA grades of steel the requirement of nitrogen extends to 0.02% to obtain high strength but this is accompanied by a drop in the notch toughness. The production of cold rolled sheets through the continuous annealing process demands a nitrogen level of 25-40 ppm.[NITK suratkal]s
  • 8. 8 3. IMPACT OF VARIOUS ELECTRIC ARC FURNACE PARAMETERS ON NITROGEN 3.1. CHARGE MIX The main source of nitrogen is the charge mix involved during steel making. To get an impression of the sources of nitrogen during the melting process, the amount of nitrogen present in each of the feed materials typically used in the EAF is shown in Table 1. Table 1: Nitrogen content of feed materials used in EAF steelmaking at JSPL, Raigarh [9] FEED MATERIAL NITROGEN CONTENT Scrap 60-100 ppm HBI 20-30 ppm DRI 60-80 ppm Liquid iron from Blast Furnace 60 ppm CPC 5000-10000 ppm Oxygen 30-200 ppm Lime (CaO) 400 ppm The charge-mix of heats analyzed was used to calculate the theoretical nitrogen content that would prevail in the bath from simple mass balance equations. Table 2: Chemical composition of HBI and DRI in JSPL, Raigarh [9] CHEMICALANALYSIS (%) HBI DRI Total Iron 91.95 88.2 Metallic Iron 83.12 79.5 Metallization 90.4 90.1 FeO 11.35 11.2 Carbon 1.33 0.07 SiO2 2.93 5.7 Al2O3 1.24 2.1 Sulphur 0.008 0.02 Phosphorous 0.053 0.07 Nitrogen (in ppm) <30 60-80
  • 9. 9 Fig.3 Influence of charge-mix on the nitrogen content (in ppm) in the bath (Source: JSPL, Raigarh) From fig.3 the nitrogen content in the bath just before tap is always less than the theoretical nitrogen content obtained when calculated from the charge-mix. Although coke plays an important role in increasing the nitrogen content, but by what factor is not clear yet. The coke is injected in the bath and above the slag layer via. carbojets to increase the foaminess of the slag. The carbon from coke reacts with FeO present in the slag to form CO gas bubbles which rush out from the molten bath thus increasing the foaminess of the slag. The slag should be foamy because it helps in covering the arc originating from the electrodes. Also, it helps in continuous removal of impurities from the steel by continuously circulating the slag and thus forming a new slag-metal interface. This conditioning is very useful to obtain cleaner steel but at the same time the slag is continuously drained out from the slag door. The removal of slag is important to avoid rephosphorization from the slag layer into the metal bath. So, the conditioning and removal of slag are simultaneously maintained by the presence of foaminess in the slag. Thus, coke injection is important and cannot be avoided in Electric Arc Furnace operation. So to have an upper and lower limit of nitrogen theoretically present, there are two curves plotted, one taking nitrogen from coke into account while another completely ruling out the possibility of the same respectively. As coke injection cannot be avoided in Electric Arc Furnace operation, the amount of nitrogen theoretically present lies in the above mentioned range. 0 20 40 60 80 100 120 140 160 0 10 20 30 40 50 60 NitrogenContent(inppm) Heat No. Practical N before tap Theoretical N considering pick-up from coke Theoretical N without considering N pick-up from coke Linear (Practical N before tap) Linear (Theoretical N considering pick-up from coke) Linear (Theoretical N without considering N pick-up from coke)
  • 10. 10 The metallic materials charged in EAF are hot metal from Blast furnace, MS scrap, skull and DRI lumps and fines. The charge-mix does play an important role in determining the nitrogen content in the steel bath. 3.2. HOT METAL The hot metal from blast furnace contains about 55-65 ppm of nitrogen in it. During tapping, the Electric Arc furnace is never completely emptied and contains liquid steel of previous heat tapped on an average of 20-30 % of furnace capacity in it termed as Hot Heel. The hot heel present contains high oxygen content along with oxidizing slag layer above it. So, when the hot metal (rich in C-content) is being charged, it comes in contact with the oxygen present in the hot heel thus getting oxidized to form CO bubbles in the initial stage. The CO gas produced flushes out nitrogen out of the metal bath and also creates a protective atmosphere over the melt that reduces the nitrogen pick-up from the atmosphere. So, the formation of protective layer in the initial stage of arcing prevents pick-up from the atmosphere. Fig.4 Influence of Hot Metal content in metallic charge on the tap Nitrogen content (Source JSPL, Raigarh) 3.3. DRI LUMPS The plot as shown in fig.5 is variation of nitrogen content with coal-based DRI lumps that are charged from the top with the help of a chute in the furnace. 0 10 20 30 40 50 60 70 30 40 50 60 70 NitrogenContent(inppm) Hot Metal in metallic charge (%)
  • 11. 11 Fig.5 Influence of DRI lumps content in metallic charge on the tap Nitrogen content (Source JSPL, Raigarh) The increased use of DRI lumps shows an increase in the nitrogen content in the bath (fig.5). The DRI used is coal-based DRI which has high nitrogen content in it. The DRI is continuously charged from the top with the help of the chute to increase the metallic content and also acts as a coolant. Due to continuous charging, the melting of DRI takes longer time and it occurs till the end of the arcing operation. This leads to lesser formation of CO bubbles and results in retention of nitrogen from DRI lumps in the steel bath. Careful and increased oxygen blowing and carbon injection to produce CO gas bubbles during the end of the arcing process can lead to removal of nitrogen but is time, material and energy wastage which is avoided in plant practice for economic reasons if not required for making special grade steels. 3.4. BUCKET CHARGE AND DRI FINES The bucket charge contains MS scrap; skull from the slag pot, tundish, etc. and DRI fines. Sometimes, Hot Briquetted Iron (HBI) is also charged through top charging depending upon its availability. The use of bucket charge and DRI fines gives lower nitrogen content in the bath and at the same time is cost effective. But the use of bucket requires a higher arcing time and higher energy as compared to that of hot metal. 0 10 20 30 40 50 60 70 20 30 40 50 60 NitrogenContent(inppm) DRI lumps in metallic charge (in %)
  • 12. 12 Fig 6. Influence of Bucket charge on the tap Nitrogen content (Source JSPL, Raigarh) Fig 7. Influence of DRI fines in metallic charge on the tap Nitrogen content (Source JSPL, Raigarh) The increased use of bucket and DRI fines in the charge mix has shown a decrease in the nitrogen content. The decrease is undoubtedly attributed to CO gas bubbles formation in the initial stage. The rate of formation is fast due smaller size and requires lesser time for melting. But the mechanism of CO formation is different as compared to that of hot metal. The addition of DRI fines, iron carbide in the form of skull and scrap contains iron oxides either unreduced or in the form of corrosion product respectively that serve as a source of oxygen for the formation of CO by an “internal” decarburization reaction, namely: O(DRI) + C(DRI-Fe)  CO(g) ……..(1) y = -0.0493x + 55.634 0 10 20 30 40 50 60 70 0 5 10 15 20 NitrogenContent(inppm) Bucket Charge (in %) y = -0.0526x + 55.438 0 10 20 30 40 50 60 70 0 5 10 15 NitrogenContent(inppm) DRI fines in Metallic Charge (in %)
  • 13. 13 Thermogravimetric studies of DRI fines and iron carbide have shown that “internal decarburization” commences above 800 0 C, possibly due to physical changes inside the DRI particles [2]. The decrease in nitrogen content observed (fig5. & fig6. ) is not significant due to two reasons. The first reason is buoyancy. Goldstein et al. in their work concluded that the nitrogen removal effect of CO bubbling from the decarburization reaction in DRI are largely lost in steelmaking operations because the bubbles are generated high in the melt as a result of the buoyancy of DRI pellets[3]. The same argument can be extended to the use of DRI fines and bucket charge which are charged in the furnace by top charging in the initial stage. Thus they remain on the higher side in the melt thereby reducing the nitrogen removal effect by CO bubbling. Though it is advantageous to have increased DRI fines content in the charge-mix from nitrogen point of view, but this is an undesirable practice if charging is done from the top. The fines been lighter in weight get blown away by the Fumes Extraction System (FES). So, this leads to reduction in the metallic yield and wastage of the DRI fines. So to have both lower nitrogen content and higher metallic yield, DRI fine injection should be carried out deep in the bath with the help of lance so that fines get a higher time to react thus resulting in efficient removal of nitrogen content. There are few models such as Jet Penetration Model which is in use in some of the plants like Mittal Steel Hamburg for many years which has been injecting DRI fines into the EAF at rates of approximately 1 Tonne min-1 .[2] The second reason is the low C-content in the coal-based DRI. The carbon content in coal-based DRI is around 0.07% (table 2.) which is very low as compared to gas-based DRI. Thus, CO gas evolved is quite low (1) which results in reduced level of nitrogen flushing from the steel bath. There is a decrease in nitrogen content observed (from fig4, fig6 and fig7) by use of hot metal, bucket charge which contains scrap, skull and DRI fines in varying amount depending upon the availability. This decrease in the nitrogen content can be attributed to formation of CO gas bubbles. It is well established that CO bubbles passing through a steel melt have a scrubbing effect on dissolved nitrogen, as nitrogen is readily absorbed into CO bubbles [2]. There has also been a study by Goldstein et al. that addition of DRI pellets helps to remove nitrogen from steel, and has quantified the fundamental kinetics of nitrogen removal by CO bubbling. [3] 3.5. OPERATIONS In Electric Arc Furnace, the process of decarburization and dephosphorization is carried out to produce steel of desired chemical composition and mechanical properties.
  • 14. 14 Fig 8. Solubility of nitrogen in iron for temperatures of 600-2000°C [4] Phosphorus removal reaction is given by [5] 2 [P] + 5 [O] = (P2O5) ……….(2) ∆ G° = −740375+ 535.365T J/mol ……….(3) ∆ G° becomes positive at T > 1382K which results in decomposition of P2O5 to P and O. Thus removal of phosphrous requires that a(P2O5) must be reduced. KP = a(P2O5) / [wt% P]2 [wt% O]5 .………(4) But, ∆ G° = -2.303RT log(Kp) ……….(5) Therefore, from equation (3) and (5), we have Log Kp = (38668/T) – 27.96 ………(6) The equation (6) shows that lower the value of temperature, higher is the Kp which means higher and effective dephosphorization of the steel bath under identical conditions of slag basicity and oxidizing potential. From nitrogen point of view, the pick-up is not possible in the EAF if process is carried out for dephosphorization where temperature is maintained around 1500-1550 0 C in which the solubility of
  • 15. 15 nitrogen is around 5-15 ppm (fig. 8). But, before tapping during the end, the temperature is raised to around 1600-1630 0 C which increases the chances of nitrogen pick-up as the solubility in this range is around 45-50 ppm (fig 8.) if the steel bath in the furnace comes in contact with the atmosphere. This occurs if the slag layer above the steel bath is drained out by the furnace operator before tapping thereby increasing the air ingression tendency from the slag door. Also, absence of slag layer results in bare- arcing due to which nitrogen from the atmosphere dissociates in ionic form which has a higher probability to dissolve in the steel bath. This results in pick-up of nitrogen.
  • 16. 16 4. NITROGEN PICK-UP DURING TAPPING During tapping, the liquid steel flows out in the form of stream which is in continuous contact with the atmosphere until the ladle is filled. The main source of nitrogen pick-up is from the atmosphere when liquid steel is tapped from the furnace at around 1600 0 C. Nitrogen being a diatomic gas follows Sievert’s law which states that solubility of a diatomic gas in a liquid is directly proportional to the square-root of its partial pressure. The main reaction for absorption of nitrogen into steel bath following Sievert’s law is given as: 0.5 N2  [N] …..(7) The equilibrium constant for equation (7) is well established to be 0.045 wt. % x atm-1/2 at 16000 C, or in other words at one atmosphere of pure nitrogen pressure, 450 ppm [N] dissolves in pure iron at 16000 C .In the case of pure Fe-C alloys, the plot (fig 9.) shows that with decreasing carbon content in iron carbon alloy, the nitrogen solubility increases. [6] Fig 9. Solubilities of hydrogen and nitrogen (at 1.0 atm) in iron-carbon alloys at 1600°C. [6]
  • 17. 17 In the case of steel tapped from the EAF, it contains various other alloying elements such as Mn, Si, S, O, P, Al, etc depending upon the charge-mix along with furnace operation conditions. The nitrogen pick-up which occurs during tapping can be controlled if the tapping duration is reduced or by some chemistry alterations. Alloying elements such as O and S acts as impurities but are very useful in controlling nitrogen pick-up from the atmosphere during tapping. O and S are surface active elements which gather on the molten steel surface thereby resisting the reaction (7)[8]. This means that both forward and backward reactions are hampered with increase in O and S content. So, the nitrogen present in the steel in the EAF process before tapping remains more or less same after the tapping is over if the O and S content is high i.e. forward reaction is retarded. To establish the above fact, the variation of nitrogen pick-up with C-content is studied. The data of heats analyzed is plotted for C-content with the nitrogen pick-up during tapping. Fig 10. Influence of C-content in the bath on the nitrogen pick-up during tapping (Source: JSPL Raigarh) There is a hyperbolic relationship between amount of carbon (wt%) in the bath to that of dissolved oxygen (wt%) in the bath (fig 9). The constant depends upon the temperature as well as the partial pressure of CO in the bath.[5] R² = 0.4771 0 2 4 6 8 10 12 14 16 18 20 0 0.05 0.1 0.15 0.2 Nitrogenpick-up(inppm) C-content in the bath (wt%)
  • 18. 18 Fig 11. Equilibrium [C] and [O] concentrations at different pressures [7] The relationship between dissolved carbon and dissolved oxygen in the molten steel bath at 16000 C of in equilibrium with pco= 1 atm is given as [5] [wt%C] [wt%O] = 0.0024 ….(8) Equation (8) shows that on increasing C-content leads to decrease in the dissolved oxygen in the bath. Also, the plot (fig 10.) shows that with increasing carbon content, the nitrogen pick-up during tapping increases. So, the relation is well established that presence of higher oxygen in the bath will lead to lesser nitrogen pick-up in the steel. The aluminum addition during tapping is done which reduces the oxygen content in steel due to formation of alumina (Al2O3). So, the carbon initially present in the steel and also which is added as an additive during tapping can now only react with left-over oxygen in the bath due to which there is reduced formation of CO thereby reducing the flushing capacity of nitrogen from the bath. So, the reduced flushing capacity and reduced O content in the bath are both responsible for higher nitrogen pick-up during tapping. It must be noted that these variations studied are done by keeping the sulphur content in the steel constant. The effect of sulphur on the pick-up is not established due to shortage of data.
  • 19. 19 5. CONCLUSION Due to the increasing production of flat products and other high end steel products via the EAF steelmaking route, the requirement for strict nitrogen control is becoming ever greater. The pick-up in the EAF is not signification during operations under proper foamy slag practice. The main source is the charge-mix in which focus should be made of increased use of hot metal or DRI fines to flush out the nitrogen by generating a slag early in the melting stage in order to shield the metal from the atmosphere; helping generate a foamy slag; and producing a CO boil within the steel bath. To obtain better results, DRI fines rich in C-content should be used and should be injected deep in the bath. The pick-up during tapping is a function of chemistry and temperature of the liquid steel when tapped in open atmospheric contact. The presence of surface active elements like Oxygen and Sulphur retard the pick-up of nitrogen from atmosphere in steel. Also, the killing practice should be carried out in such a way that the carbon in the bath is allowed to react with excess oxygen producing CO to flush out the nitrogen and at the same time form a protective layer over the steel bath to avoid further pick-up.
  • 20. 20 6. REFERENCES 1. P R Sureshkumar, D R Pawar, V Krishnamoorthy, How to make N2 listen to you in steel making!, International Journal of Scientific & Engineering Research Volume 2, Issue 10, October-2011, ISSN 2229-5518, pp. 1-5 2. Dorel Anghelina, Gordon A. Irons, Geoffrey A. Brooks, Nitrogen Removal from Steel by DRI Fines Injection, AISTech 2005 Proceedings - Volume I, pp. 403-409 3. D. A. Goldstein, R. J. Fruehan, Mathematical model for nitrogen control in oxygen steelmaking, Metallurgical and Materials Transactions B, October 1999, Volume 30, Issue 5, pp. 945-956 4. www.keytometals.com/page.aspx?ID=CheckArticle&site=kts&NM=202 5. Amit chaterjee and A Ghosh 6. Siddhartha Misra, Yun Li, Il Sohn, Hydrogen and Nitrogen Control in Steelmaking at U. S. Steel, Association for Iron and Steel Technologies 7. Electric Arc Furnace Simulation User Guide ,Version 1, steeluniversity.org 8. Jie Fu, Shixiang Zhou, Ping Wang, Lin Di, Jian Zhu, Effects of Temperature and [S] on the kinetics of Nitrogen Removal from Liquid Steel, J. Material Science Technology, Volume:7 No.2,2001,pp 233-236. 9. Ashutosh Sharma, Joy Dutta, Amit Khokhar, Sanjay Anand, B. Lakshminarasimham, Nitrogen Control during EAF Steelmaking at Jindal Steel & Power Limited,