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<p>The reduction and precise control of ferroalloys in steelmaking are critical for lowering energy and resource consumption, minimizing environmental pollution, reducing production costs, improving product quality, and advancing the intelligent operation of steel plants. A novel intelligent control system for ferroalloy reduction is proposed and implemented in industrial production. The system integrates ferroalloy raw material quality evaluation, prediction of key steelmaking parameters, accurate batching and cost optimization, and control of specific energy consumption (SEC) and carbon emission (CE). The results demonstrate that improving ferroalloy raw material quality enhances alloy yield during the steelmaking process. Accurate prediction of steel output, composition, and elemental yield is essential for precise ferroalloy dosing. Optimization of alloy batching structures effectively reduces ferroalloy consumption and enables “narrow composition” control of molten steel. Following implementation of the proposed strategy, production costs for Q345B and GCr15 steel grades decrease by 39.76 and 4.07 CNY/t, respectively. In addition, the combined annual reductions in SEC and CE reach 8,099,350 kg of coal equivalent and 3106.25 t CO<sub>2</sub>, respectively. These findings indicate that ferroalloy reduction and precise control technologies are effective strategies for achieving green, low-carbon, efficient, and sustainable development in the iron and steel industry, aligning with global carbon neutrality goals and China’s strategic priorities.</p>

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Reduction strategies of ferroalloy in steelmaking process: raw material monitoring, process optimization, intelligent control system, economic and social benefits

  • 期刊论文

  • 发表日期：

    2026年5月27日

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  • Xin Liu,
  • Chao Xue,
  • Zhi-Wen Wang,
  • Yan-Ping Bao,
  • Li-Hua Zhao

摘要

The reduction and precise control of ferroalloys in steelmaking are critical for lowering energy and resource consumption, minimizing environmental pollution, reducing production costs, improving product quality, and advancing the intelligent operation of steel plants. A novel intelligent control system for ferroalloy reduction is proposed and implemented in industrial production. The system integrates ferroalloy raw material quality evaluation, prediction of key steelmaking parameters, accurate batching and cost optimization, and control of specific energy consumption (SEC) and carbon emission (CE). The results demonstrate that improving ferroalloy raw material quality enhances alloy yield during the steelmaking process. Accurate prediction of steel output, composition, and elemental yield is essential for precise ferroalloy dosing. Optimization of alloy batching structures effectively reduces ferroalloy consumption and enables “narrow composition” control of molten steel. Following implementation of the proposed strategy, production costs for Q345B and GCr15 steel grades decrease by 39.76 and 4.07 CNY/t, respectively. In addition, the combined annual reductions in SEC and CE reach 8,099,350 kg of coal equivalent and 3106.25 t CO2, respectively. These findings indicate that ferroalloy reduction and precise control technologies are effective strategies for achieving green, low-carbon, efficient, and sustainable development in the iron and steel industry, aligning with global carbon neutrality goals and China’s strategic priorities.