Evolution of inclusion populations in Al-killed steel during the steelmaking process

The increasing demand for higher steel inclusion cleanliness has motivated control over the formation and evolution of inclusions during the production process. To generate knowledge of the formation and evolution of inclusions during the production of Al-killed steel slabs, the evolution of the chemical composition and size distribution of inclusions throughout the process, including ladle furnace (LF) treatment and continuous casting (CC), was studied. Liquid steel sampling was conducted throughout the process. The chemical composition was measured using the EDS technique, and the size distribution analysis was performed with the population density function (PDF) approach. The upper tail of the size distributions was analyzed by generalized extreme value (GEV) theory. Evolution of the chemical composition of inclusions involved the following path: solid Al2O3 solid Al2O3-MgO partly liquid Al2O3–MgO–CaO fully liquid Al2O3–MgO–CaO. The PDF analysis accounted for the evolution of the size distribution, which was supposed to be driven by the balance of the coalescence/growth and collision/breakage of inclusions and their removal. Finally, the GEV approach allowed us to describe the evolution of large inclusions and compare inclusion populations in terms of survival probability