Precise Regulation of Carbon Potential in Molten Steel and Achievement of Efficient Low-Carbon Steelmaking: Technical Pathways
I. Raw Material Selection: High-Purity Graphitized Petroleum Coke as the Foundation
Core Indicator Control
- Fixed Carbon ≥ 98%: For every 1% increase in purity, cast part strength rises by 15%, feedstock volume decreases by 8%, and smelting energy consumption is directly reduced.
- Sulfur ≤ 0.03%: Exceeding sulfur limits by 0.02% can cause a 40% surge in porosity in engine cylinder blocks, necessitating strict screening of low-sulfur coke (e.g., South African import coke with sulfur ≤ 0.3%).
- Nitrogen ≤ 150 ppm, Ash ≤ 0.5%: Excess nitrogen disrupts graphite morphology in ductile iron, while high ash content forms slag inclusions, compromising steel performance.
Physical Property Verification
- Metallic Luster Test: Authentic products exhibit glass-like crystalline fracture surfaces, while inferior grades appear dull like charcoal, reflecting crystalline integrity.
- Laser Particle Size Analysis:
- 1–3 mm particles for precision casting (dissolution rate matches molten steel flow velocity).
- 3–5 mm particles for electric arc furnace (EAF) steelmaking (delays oxidation losses).
- Powder content exceeding 3% forms a barrier layer, inhibiting carbon absorption.
II. Process Optimization: High-Temperature Graphitization and Intelligent Feeding
3000°C High-Temperature Quenching Technology
- Carbon Atom Realignment: In sealed Acheson furnaces, coke blocks undergo 72-hour treatment at ≥3000°C, forming honeycomb crystalline structures. Sulfur residues drop to ≤0.03%, with fixed carbon exceeding 98%.
- Energy Consumption Control: Each ton of product consumes 8,000 kWh, with electricity accounting for >60% of costs. Optimizing furnace temperature curves (e.g., maintaining ≥2800°C) reduces unit energy consumption.
Intelligent Feeding System
- 5G+AI Real-Time Monitoring: Sensors track iron’s electromagnetic properties, combined with carbon equivalent prediction models to precisely calculate carburizer addition rates.
- Robotic Arm Grading Feeding:
- Coarse particles (3–5 mm) for sustained carburization.
- Fine powders (<1 mm) for rapid carbon adjustment, minimizing oxidation losses.
III. Integration of Low-Carbon Steelmaking Technologies
EAF Green Production
- Waste Heat Recovery: Utilizes high-temperature flue gas for power generation, saving energy and indirectly reducing CO₂ emissions.
- Coke Substitution: Replaces partial coke with graphitized petroleum coke carburizers, reducing non-renewable fossil fuel consumption.
- Scrap Preheating: Shortens smelting cycles, lowers energy use, and aligns with “near-zero carbon” EAF trends.
Hydrogen-Based Steelmaking Synergy
- Blast Furnace Hydrogen Injection: Blowing hydrogen-rich gases (e.g., H₂, natural gas) replaces partial coke, cutting carbon emissions.
- Hydrogen Shaft Furnace Direct Reduction: Uses hydrogen as a reductant for direct iron ore reduction, reducing emissions by >60% compared to traditional blast furnaces.
IV. Quality Control: Full-Process Traceability and Inspection
Raw Material Blockchain Traceability
Scanning QR codes provides access to customs declarations, sulfur test videos, and production batch data, ensuring compliance.
Electron Microscope Inspection
Quality inspectors adjust crystalline density via electron microscopy, eliminating silica-alumina inclusions to prevent accidents in high-end castings like nuclear valve steel.
V. Application Scenarios and Benefits
High-End Casting
- Nuclear Valve Steel: Sulfur suppression locks content below 0.015%, preventing stress corrosion under high-temperature/pressure conditions.
- Automotive Engine Blocks: Reduces defect rates from 15% to 3% and significantly lowers porosity.
Specialty Steel Production
- Aerospace High-Strength Steel: Graded addition of 1–3 mm particles achieves >97% carbon absorption, eliminating quenching cracks in 42CrMo steel and raising yield rates above 99%.
New Energy Applications
- Lithium-Ion Battery Anodes: Processed into 12 μm modified particles, boosting energy density beyond 350 Wh/kg.
- Nuclear Reactor Neutron Moderators: Each 1% purity variation in high-purity grades causes 10% fluctuations in neutron absorption rates.
Post time: Feb-12-2026