CHARGE MATERIALS

Elkem Foundry Products

Advanced materials shaping the future

PIG IRON
• Used to dilute and reduce Mn and other alloying elements to
acceptable levels
• Source for easily dissolved C
• Different types available depending on specification needed (Si, C, P,
Ti and S)
• max 0.02% P
• 0.015% S
• max 0.04% Ti
• Different production methods may give different structure and
ultimately different energy consumption and dissolution

2 Advanced materials shaping the future

EFFECT OF TEMPERATURE AND CHARGE COMPOSITION

3 Advanced materials shaping the future

STEEL SCRAP
• should come from known source and be bought to a specification
• should be clean, dry and free of oil and paint
• preferably thin sections to melt and dissolve faster
• Elements to pay attention to: Mn, P, V, Mo, Ti, Cr, Sb, Sn and Zn
• should be stored dry
• can be preheated to ensure that it is dry
• can lead to more fluid slag and cause slag defects
• pay attention to developments within steel qualities and more use of
alloying elements
• can be a cheaper alternative to pig iron in some areas

4 Advanced materials shaping the future

3 MAJOR TYPES OF STEEL SCRAP

• Unalloyed steels: Mn content

of maximum 1,65%
• Stainless steels: minimum
10,5% Cr and maximum
1,2% C
• Other alloyed steels

Development of steel qualities for the

automotive industry 1975 - 2010
Composition of unalloyed steels – Max Content

Al: 0,3% Cr: 0,3% Nb: 0,06% Si: 0,6% W: 0,3%

B: 0,008% Cu: 0,4% Ni: 0,3% Te: 0,1% Zr: 0,05%
Bi: 0,1% La: 0,1% Pb: 0,4% Ti: 0,05%
Co: 0,3% Mo: 0,08% Se: 0,1% V: 0,1%
Source: Giesserei 12/2007

5 Advanced materials shaping the future

RETURNS

• Close in composition to desired final composition

• Provides low melting point for initial part of charge
• Should be clean and free from oxidation and burnt-on sand
• Should ideally be separated according to grade
• Cut up ingates to increase charge density
• Can be risky to buy due to poor segregation and S-levels

6 Advanced materials shaping the future

ADJUSTMENT OF C-LEVEL IN MELT

• All ductile irons have a near-eutectic compositions to achieve the best

casting properties
• C and Si are the main elements influencing the composition in relation
to the eutectic point
• C-content is adjusted in the base melt prior to any melt treatments
and tapping, while Si is adjusted through melt treatments with
materials like MgFeSi and Inoculants
• reasons for this are:
• C needs time and temperature to dissolve
• stirring or bath movement is needed to dissolve C and not to float or get
entrapped by slag
• solubility of C is lower with increasing Si

7 Advanced materials shaping the future

FACTORS TO CONSIDER WHEN SELECTING RECARBURISER

• the higher the C-content the higher the recovery

• ash-content should be low
• low moisture content
• low content of volatiles
• specified and low S-content
• specified and low N-content
• crystal structure

8 Advanced materials shaping the future

TYPICAL CHEMICAL COMPOSITION OF COMMON RECARBURISERS

Elgraph

9 Advanced materials shaping the future

TYPES OF RECARBURISERS

• Synthetic graphite: calcined petroleum coke and coal pitch mixed and
baked into desired shapes prior to a two-stage heating process, which
adjusts final S and N levels. Most versatile.
• Natural graphite: limited availability and variable quality
• Calcined petroleum coke: raw material comes from oil refineries and
is heat treated/calcined to ensure removal of moisture and volatiles.
Cheaper production than synthetic graphite and more difficult to
disolve.
• Carburisers derived from coal (not commonly in use)
• metallurgical coke: produced in coke ovens from raw petroleum coke
• brown coal char: carbonising of brown coal
• Silicon Carbide: combined addition of Si and C

10 Advanced materials shaping the future

RECARBURISER

• Used to adjust the C content of the melt prior to tapping

• Can be crystalline or non-crystalline,
• crystalline: crushed electrode scrap, graphitic recarburisers
• non-crystalline: petroleum coke
• Should be clean and dry
• S-level should be specified and in some cases also N
• Select type to fit time/point off addition – lower quality non-crystalline)
for addition to charge and high quality (crystalline) for late trimming
addition
• expected recovery rate is minimum 80%

11 Advanced materials shaping the future

SiC

• Can be used to tie up oxidation products in the melt or as Si or C

adjustment
• dissolves slow, so allow sufficient time after addition to dissolve
• should be restricted to maximum 1% of total liquid melt in order to avoid
undisolved SiC-inclusions
• add to furnace and not to ladles as it dissolves slowly
• can help keep up part of furnaces (above coil) clean from slag
• can increase refractory wear in upper part of the furnace (above coil)

12 Advanced materials shaping the future

 CHARGE COMPOSITION

Advanced materials shaping the future

CONSIDERATIONS WHEN SELECTING MELTING PROCESS FOR
MELTING OF THE DUCTILE IRON BASE

• cost of equipment
• conversion cost of 1 ton solid into 1 ton liquid
• production volume
• type and number of different alloys to be produced
• metallic charge cost and availability
• energy cost and availability
• environmental considerations

14 Advanced materials shaping the future

BASIC REQUIREMENTS TO THE MELTING PROCESS

• Liquid base iron with correct chemical analysis

• Liquid base iron with correct physical condition (nucleation potential)
• Liquid base iron at the correct amount and time to support the
moulding line
• Lowest possible cost per ton liquid base iron.

15 Advanced materials shaping the future

“TYPICAL” CHARGE COMPOSITION

1. 0-80 % Pig Iron low in Mn- and trace elements

2. 0-30 % Return (preferably same quality)
3. 20-50 % Steel scrap low in Mn, preferably no Ti, V, B
4. 0,2 – 2 % Recarburiser
5. 0,2 – 1% FeSi 75 low in Al- and Ca
6. Other alloying elements (Mn, S, Sb, etc)

16 Advanced materials shaping the future