An innovative electroslag remelting furnace with a water-cooled electrode was introduced to recycle the rejected electrolytic manganese metal (EMM) scrap. To clarify the desulfurization process in the rejected EMM scrap, a transient three-dimensional comprehensive numerical model was elaborated. Using the magnetic potential vector approach, the respective electromagnetic fields were calculated via the Maxwell equations. The Lorentz force and the Joule heating fields were derived as phase distribution functions and interrelated via the momentum and energy conservation equations as source terms, respectively. The molten manganese metal droplet motion, as well as the fluctuation of the slag–metal interface, was described by the volume-of-fluid (VOF) approach. Besides, the solidification was modeled via the enthalpy-based technique. A thermodynamic module was established to estimate the sulfur mass transfer rate between the molten manganese metal and the molten slag. Furthermore, a factor related to the magnitude and frequency of the alternating current and the physical properties of the melt was introduced to include the electro-emulsification phenomenon. An experiment has been carried out with a commercial-scale ESR device. The predicted values of the slag temperature and sulfur content in the final manganese ingot were found to agree reasonably with the corresponding measured data. Under continuous melting of the rejected EMM scrap, molten manganese metal droplets are formed at the domain inlet, grow, and fall down. Highly conductive molten manganese metal droplets significantly change distributions of the current streamline, the Joule heating, and the Lorentz force around and within it. Moreover, droplets are inclined to rotate and move inside the mold. With the renewal of the slag–manganese interface, sulfur in the molten manganese metal is constantly transferred to the molten slag. With the applied current ranging from 3000 to 4000 A, the average sulfur content of the manganese ingot dropped from 0.0447 to 0.0291 pct, and thus, the desulfurization rate rose from 55.3 to 70.9 pct.

Band segregation has been found in the H13 die steel produced by the electroslag remelting (ESR) technology. Chemical and metallographic studies have been carried out on a one ton ESR ingot of H13 die steel, so as to understand the formation mechanism of the band segregation. The results indicate that the T.O content and S content decreased because of cleanliness improvement of ESR process. Transverse macrosegregation of S content decreased after ESR. The overall removal ratio of the inclusion is around 65.8%. The original complex inclusions would be modified to the CaO•Al₂O₃ inclusions. Al₂O₃ and MnS inclusions can be found after ESR. Both of Al₂O₃ and MnS inclusions were found to be the core of primary carbides. The net like structure in ESR ingot and banded structure in the forged steel were observed. V, Mo, Cr and S are rich in the segregation areas of ESR ingot. Besides, black and white segregation bands can be observed on the forged steel samples after etching. Uneven distribution of carbides rich in V, Mo and Cr was observed in banded structure.

In order to recognize the dripping and the carburizing behaviors of the molten iron within the coke packed bed in the flash ironmaking process, a transient three-dimensional numerical model was developed. The volume of fluid (VOF) approach is used to describe the movement of the molten iron and the argon gas. The porous medium module is employed to define the momentum, heat, and mass transfer between the coke packed bed and the molten iron. Moreover, a factor is introduced to consider the influence of the ash film on the carburization process. A reasonable agreement between the experiment and simulation is obtained. The results indicate that the molten iron flows downward from the upper crucible to middle crucible. After entering the middle crucible, the molten iron spreads around within the coke packed bed and simultaneously moves downward. The carbon is, therefore, transferred from the coke to the molten iron. With the 47-mm-height coke packed bed, the carbon content in the molten iron after the carburization decreases from 3.19 to 1.97 pct, while the coke diameter ranges from 2 to 5 mm. With the 2-mm-diameter coke, the carbon content in the molten iron after the carburization increases from 2.84 to 4.81 pct, while the coke packed bed height increases from 37 to 97 mm.