Manufacturing, Engineering and Technology Fabrication and Extraction

Vertical Converter Slag Magnetite Content Control Training

SAQA US 110120 | NQF 3 | Credits 7 | Duration 4 Days
From $1,107 per delegate

Description

This course equips learners with the knowledge and skills to control magnetite content in vertical converter slag during steelmaking. It focuses on monitoring, adjusting, and optimizing slag chemistry to improve process efficiency, reduce waste, and ensure compliance with safety and environmental standards.

Learning Outcomes

  • Apply principles of slag chemistry to monitor magnetite content in vertical converter operations.
  • Analyze slag samples using standard testing methods to determine magnetite levels.
  • Evaluate process variables affecting magnetite formation and implement corrective actions.
  • Implement control measures to maintain magnetite content within specified limits.
  • Demonstrate adherence to safety protocols during slag handling and sampling procedures.
  • Document and report magnetite content data for process optimization and compliance.

Target Audience

Process controllers, metallurgical technicians, and production supervisors working in steel manufacturing or smelting operations who are responsible for slag management and quality control.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Fundamentals of Slag Magnetite and Converter Operations

Objectives:
• Explain the role of slag in the converter process and the significance of magnetite content.
• Identify key factors influencing magnetite formation and distribution in slag.
• Describe the basic principles of slag chemistry and its impact on steel quality.
• Perform initial slag sampling and basic magnetite content estimation using visual methods.

Topics:
• Introduction to converter slag: composition, functions, and importance.
• Magnetite (Fe3O4) in slag: sources, formation mechanisms, and effects.
• Overview of converter process stages and slag generation.
• Factors affecting magnetite content: oxygen potential, temperature, and slag basicity.
• Basic slag sampling techniques and safety considerations.
• Visual assessment of slag: colour, texture, and magnetite indicators.
• Introduction to slag handling and environmental considerations.

Day 2: Measurement and Analysis of Magnetite Content

Objectives:
• Apply analytical methods to quantify magnetite content in slag samples.
• Interpret laboratory results and correlate them with process parameters.
• Use handheld instruments for rapid field measurement of magnetite.
• Identify common errors in sampling and analysis and implement corrective actions.

Topics:
• Laboratory analysis techniques: XRF, XRD, and chemical titration for magnetite.
• Calibration and use of handheld magnetite meters and magnetic susceptibility devices.
• Sampling protocols: representative sampling, sample preparation, and chain of custody.
• Data interpretation: correlating magnetite content with slag viscosity and foaming.
• Quality control: duplicate samples, blank tests, and proficiency testing.
• Troubleshooting measurement discrepancies and instrument maintenance.
• Case study: analysing slag samples from different converter heats.

Day 3: Control Strategies for Magnetite Content Optimisation

Objectives:
• Develop strategies to control magnetite content through process adjustments.
• Implement flux addition practices to achieve target slag composition.
• Monitor and adjust oxygen blowing patterns to minimise magnetite formation.
• Evaluate the impact of magnetite control on refractory life and yield.

Topics:
• Process control parameters: oxygen flow rate, lance height, and blowing time.
• Flux management: types of fluxes (lime, dolomite, fluorspar) and their effect on magnetite.
• Slag conditioning: use of carbonaceous materials and reductants.
• Real-time monitoring: temperature, slag splashing, and slag foaming indicators.
• Optimising slag basicity and FeO content for magnetite control.
• Impact of magnetite on refractory wear and slag carryover.
• Practical exercises: adjusting process parameters in a simulated environment.
• Standard operating procedures for magnetite content control.

Day 4: Advanced Applications and Process Integration

Objectives:
• Integrate magnetite control into overall converter process optimisation.
• Analyse historical data to identify trends and improve control strategies.
• Implement continuous improvement initiatives for slag management.
• Demonstrate competency in troubleshooting and resolving magnetite-related issues.

Topics:
• Advanced data analytics: trend analysis, statistical process control (SPC) for magnetite.
• Integration with downstream processes: ladle treatment and continuous casting.
• Environmental and safety aspects: slag disposal, dust control, and spill prevention.
• Troubleshooting common problems: high magnetite, slag foaming, and refractory wear.
• Continuous improvement: Kaizen, root cause analysis, and corrective action plans.
• Assessment: practical demonstration of sampling, measurement, and control techniques.
• Review of key learnings and final Q&A session.
• Course evaluation and certification.

Practicals

No practicals for this training.

This course is made up of exercises and case studies delivered alongside the theory — no separate practical sessions are required to complete it.

Summatives

Each delegate is assessed continuously throughout the course and a final summative test at the end.

Daily Exercises — 30%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 30% to the final total.

Final Test — 70%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 70% to the overall mark.

Final Total
Component Out of Weight
Daily Average (multiple choice) 100% 30%
Final Test (multi-answer multiple choice) 100% 70%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Daily Average 30% + Final Test 70%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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