Thermodynamic Guidelines for Minimizing Chromium Losses in Electric Arc Furnace Steelmaking

In the production of stainless steel, chromium losses, particularly in the electric arc furnace (EAF) phase, pose a challenge. This study addresses these issues by reviewing and analyzing the thermodynamics of the Fe-Cr-C-O-(Si) system, highlighting discrepancies in existing literature regarding Gibbs free energies, interaction parameters, and other thermodynamic data. We developed a simple to use thermodynamic model to simulate the oxidation process using established data from scientific literature. The model calculates the equilibrium solubilities of chromium and carbon, showing how process variables like temperature, partial pressure of carbon monoxide, and silicon concentration influence chromium oxidation. The findings confirm that higher temperatures and the presence of silicon significantly reduce chromium loss by favoring carbon oxidation over chromium. The research concludes by providing practical guidelines for minimizing chromium losses in EAFs, such as protecting scrap with carbon, silicon, and aluminum; controlling oxygen intake; and ensuring a high melt temperature during decarburization. These guidelines aim to improve the economic efficiency and sustainability of stainless steel production. The paper is an expanded version of a prior conference paper.