Technical Information 10

Tundish Cover Ladle Nodularizing

Magnesium treatment for nodularization of ductile iron can be made by several different
treatment processes. The tundish cover ladle process will under most conditions, be a
convenient, effective and reliable process with good economy. The process provides good
consistency and high recoveries of magnesium over a wide range of treatment sizes. A
well-operated system will give between 60 – 80 % recovery of magnesium while the opera-
ting and maintenance costs normally fall well below most other commercial processes.
Tundish ladle treatments also offer virtually no flare, about 90 % fume reduction, no metal
splashing and minimum carbon and temperature losses. The figure below shows an
example of a tundish cover ladle.

Figure 1: Schematic representation of a tundish

cover ladle with dual alloy pockets.

Calculation of Filling Hole Dimensions

The following formula can be used to calculate the diameter of the tundish lid filling hole:

W
d = 0.07
t ⋅h

where d is the filling hole diameter in centimetres (cm), W is the liquid iron batch weight in
grams (g), t is the pouring time in seconds (s), and h is the ferrostatic height of metal in the
tundish basin in centimetres (cm). Note: h is the height of metal, not the height of the basin
itself.

Base metal sulphur contents should preferably not exceed 0.02% before treatment to
ensure maximum efficiency of the tundish ladle. If sulphur levels are higher, a desulphuri-
zing step is recommended prior to nodularization.

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Technical Information 10 2

Magnesium Alloy Selection and Addition

The tundish cover process may be used with most magnesium ferrosilicon alloys contai-
ning between 3 to 12 % magnesium but generally alloys containing 4 – 6% Mg are used.

Typically an alloy with the composition given in the table would be Element Contents
used to treat base iron composed of a mixture of steel scrap, pig iron Si 45%
and returns. Alloy size grading of about 1 – 10 mm is most suitable Mg 6%
for small treatments while sizes up to 4 – 35 mm are preferable for
Ca 1%
larger treatments. See Elkem Technical Information Sheet No. 20 for
RE 1%
more details on selection of nodularizers in ductile iron.
Al max. 1%
The amount of alloy added usually lies between 1.2 and 1.8 weight % Fe Balance
depending on the base sulphur content, the metal temperature, the
magnesium content of the alloy and the consistency with which the
process is carried out.

Cover Material Selection

It is recommended to use a cover material over the magnesium alloy in the reaction
chamber in order to obtain maximum treatment economy. The cover should retain the alloy
in the chamber for as long as possible before the reaction starts. Covers commonly consist
of clean steel plate or clippings of a grade similar to that used in the melt charges. Cast
iron cover plates can be cast from the spare metal left at the end of a cast thus avoiding
the carbon dilution due to the steel cover. However, the best results are obtained using a
ferrosilicon alloy as a cover material.

Example of Recovery Improvements

Figure 2: Schematic representation of recovery improvements as a

function of sulphur content, treatment temperature, and ladle
design modifications. The initial case of 2.0 wt% addition rate
represents a situation with 0.03% S and 1520°C treatment
temperature.