Ceeeet “HOT TOPICS” ‘Gime’ the use of subscribing companies - Not foe general dstribation {or general dsribation Issue #9, 2000 Carbon Dissolution in Iron Have you wondered about how quickly the carbon or graphite goes into solution in the molten iron? Melting personnel are adding carbon or graphite to furnaces on a daily or hourly basis, but no one has videotaped the actual dissolution of this material into molten iron the carbon pick 1. Carbon or graphite has a very high melting point, and actually it sublimes at 6090F. Its boiling point is 8720F. It never melts in iron; it dissolves just like sugar in water. Iron acts like a solvent for carbon. 2. Ash content should be low for increasing the recovery of 6. carbon, According to Art Spengler, Dr. Carl Loper Jr. and others, high ash content in the material reduces the recovery rate, 3. High sulfur content in carbon/ graphite tends to slow down carbon recovery. The reduction in recovery rate is not as strong as that of ash content. 4, Volatiles and moisture in the carbon raiser are seldom a problem unless they become excessively high, Moisture and molten iron never mix in any proportion. Some graphite has excessive volatiles and produces exploding particles when added to the molten metal bath. 5. Sizing plays an important role in the recovery of carbon. Most carbon and graphite products are sized between %4” and 100 mesh. Larger sized materials are used for fumace additions and finer materials for ladle additions. Materials sized too large float and take long to dissolve and, in the meantime, they can oxidize and will result in lower recovery. Materials much below 100 mesh will have too many fines, which will result in excessive loss to dust collection and will result in lower recovery. Finer material has greater surface area and can absorb moisture and other gases, which may be detrimental to the quality of the iron. Also, to get better recovery, additions should be stirred in or mixed in well with the iron. The type of melting unit used has a significant effect on the mixing of materials. Carbon being light tends to float, if not stirred. Coreless induction furnaces are very efficient in mixing carbon with iron, Arc furnaces have violent action under the electrodes, but only a ripple effect at the sidewalls, Different sources of carbon and graphite have different degrees of carbon recovery. Synthetic graphites, like crushed electrodes jand other materials have high recoveries due to the factors discussed in 1 through 5. Also, carbon additives derived from acetylene and ethylene giverecovery due to ion and sizing control, Calcined petroleum cokes and natural graphite result in lower recoveries due to high ash content, Unconventional materials such as rice hulls, tars and pitches and even “poling” with tree limbs have been tried as carbon raisers in iron, Schematic representations of earbon/ graphite particles in iron: Molten metal Carbon! Graphite particle Slag or ash adhering to the carbon particle Figure 1. Carbon particle is partially submerged in molten iron. ‘The ash softens, partially melts into a refractory-like paste, and sticks to the carbon, The only way to recover the carbon is to stir, agitate or rub off the softened ash barrier. Figure 2. Shows an enlarged view of graphite particle with slag coating. As carbon diffuses into the slag (ash) barrier, it then must diffuse out into the molten metal. The rate of diffusion will be increased considerably if the slag barrier is removed by a) stirring or agitation, or b) not being there in the first place (as in high purity carbon/ graphite). Sulfur also diffuses into the slag barrier, and then diffuses into the metal. In doing so, it displaces carbon, slowing the carbon recovery, see Fig, 2 Molten, Carbon! metal saraphite particle Figure 3. Carbon particle shown above has very litte slag barrier. The carbon particles shown in Fig. 3 result from the use of high purity material or by actively stirring the melt. ‘The carbon is relatively free to diffuse into the molten iron with minimal barrier between the carbon and the molten iron, Conclusion The rate of carbon dissolution in iron is dependent upon the ash content of the carbon additive and the degree of stirring the metal and particle encounter. Other less significant factors affecting the recovery are size distribution, sulfur content, and moisture and volatiles in the carbon raisers. All considered, the purity of the carbon additive is probably the determining factor for efficient carbon recovery in iron, For assuring maximum safety of everyone, keep all materials dry in the melt