Review on monitoring and prevention technologies of splashing induced by inappropriate slag foaming in BOF

Basic oxygen steelmaking (BOS) is the most frequently used method to produce molten steel, which is being developed to meet the requirements of being safe, efficient, clean, and intelligent. During the BOS process, splashing events cause undesirable consequences, such as casualties, low efficiency, environmental pollution, and uncontrollable operation. The causes of three types of splashing (eruptive, foaming, and metallic splashing) were unraveled and it is concluded that inappropriate foaming is the root cause of splashing. A variety of monitoring techniques for splashing have been developed to measure real-time slag foaming in a basic oxygen furnace (BOF). The audiometry technique with flexible operation and high accuracy was comprehensively introduced with a practical application. Based on the formation mechanisms, the countermeasures for the three types of splashing were proposed to regulate slag foaming in a BOF by integrating diverse measures in terms of raw materials, slag forming, blowing pattern, and the use of splashing regulating agents. Future work should emphasise an automatic action for these prevention measures in response to the splashing risk from the monitoring technology, promoting the progress of intelligent steelmaking.