Metallic Recovery and Ferrous Melting Processes

Abstract

The effects of melting atmosphere and charge material type on the metallic and alloy recovery of ferrous charge materials were investigated in two sets of experiments (Tasks 1 and 2). In addition, thermodynamic studies were performed (Task 3) to determine the suitability of ladle treatment for the production of ductile iron using scrap charge materials high in manganese and sulfur. Task 1--In the first set of experiments, the charge materials investigated were thin steel scrap, thick steel scrap, cast iron scrap, and pig iron in the rusty and clean states. Melting atmospheres in this set of experiments were varied by melting with and without a furnace cover. In this study, it was found that neither covered melting nor melting clean (non-rusty) ferrous charge materials improved the metallic recovery over the recovery experienced with uncovered melting or rusty charge materials. However, the silicon and manganese recoveries were greater with covered melting and clean materials. Silicon and manganese in the molten iron react with oxygen dissolved in the iron from uncovered melting and oxidized iron (surface rust). Silica and manganese silicates are formed which float to the slag decreasing recoveries of silicon and manganese. Cast iron and pig iron had higher metallic recoveries than steel scrap. Carbon recovery was affected by the carbon content of the charge materials, and not by the melting conditions. Irons with higher silicon contents had higher silicon recovery than irons with lower silicon contents. Task 2--In the second set of experiments, briquetted turnings and borings were used to evaluate the effects of briquette cleanliness, carbon additions, and melting atmosphere on metallic and alloy recovery. The melting atmosphere in this set of experiments was varied by melting in air and with an argon atmosphere using the SPAL process. In this set of experiments, carbon additions to the briquettes were found to have the greatest effect on metallic and alloy recovery. The use of an argon atmosphere was also found to increase recoveries, but to a lesser extent than with carbon additions to the briquettes. Task 3--Finally, thermodynamic studies were carried out to evaluate the potential for removing manganese and sulfur from iron melts for the production of ferritic ductile iron. Thermodynamic calculations indicated that manganese and sulfur might be removed from iron melts by careful control of the temperature and slag. In laboratory tests however, it was shown that the removal of sulfur was much less successful than that indicated by the thermodynamic analyses.