EP3425071B1 - Melting flux for slagging and deoxidating molten metal - Google Patents

Melting flux for slagging and deoxidating molten metal Download PDF

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Publication number
EP3425071B1
EP3425071B1 EP18181322.1A EP18181322A EP3425071B1 EP 3425071 B1 EP3425071 B1 EP 3425071B1 EP 18181322 A EP18181322 A EP 18181322A EP 3425071 B1 EP3425071 B1 EP 3425071B1
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EP
European Patent Office
Prior art keywords
melting
flux
weight
flux according
metal
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EP18181322.1A
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German (de)
French (fr)
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EP3425071A1 (en
Inventor
Maurizio Sala
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Foundry Ecocer Srl
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Foundry Ecocer Srl
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21C—PROCESSING OF PIG-IRON, e.g. REFINING, MANUFACTURE OF WROUGHT-IRON OR STEEL; TREATMENT IN MOLTEN STATE OF FERROUS ALLOYS
    • C21C7/00—Treating molten ferrous alloys, e.g. steel, not covered by groups C21C1/00 - C21C5/00
    • C21C7/0087—Treatment of slags covering the steel bath, e.g. for separating slag from the molten metal
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/06—Obtaining aluminium refining
    • C22B21/062—Obtaining aluminium refining using salt or fluxing agents
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B21/00—Obtaining aluminium
    • C22B21/06—Obtaining aluminium refining
    • C22B21/064—Obtaining aluminium refining using inert or reactive gases
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
    • C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
    • C22B9/10—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals with refining or fluxing agents; Use of materials therefor, e.g. slagging or scorifying agents

Definitions

  • the present invention relates to a melting flux for slagging and deoxidating molten aluminium and its alloys.
  • Slagging is the process of eliminating residues and slag from the product being melted inside the furnace, in particular suspended oxides from metal.
  • Double chamber furnaces are known, in which metal scrap is melted and the slag produced by the melting operation is eliminated.
  • the metal is normally melted in a first closed chamber at over 700°C: at the end of the melting operation, a slag layer remains, floating on the molten metal bath.
  • Said slag comprises harmful metals, for example aluminium and magnesium which is highly flammable.
  • Said first chamber may not be opened, since the contact with the air would burn the highly flammable slag.
  • the molten metal is then necessarily poured into a second chamber by means of an internal duct.
  • the slag layer tends to obstruct said duct causing serious damage to the furnace, also limiting the slagging in said second chamber which requires conditions suitable for the opening.
  • JP-2004176095 describes a melting lime-base flux for slagging molten metal containing aluminium hydroxide.
  • US-3309196 discloses a melting flux for reduction of oxidized iron material, comprising alkali salt and aluminium oxide.
  • US-3650730 discloses a melting flux for removing impurities from aluminuim or aluminuim alloys, comprising a chloridizing agent.
  • a melting flux of the present invention is adapted to be employed in melting furnaces, in particular in double chamber furnaces.
  • Said melting flux is a compound comprising aluminium hydroxide and an alkali salt mixture, and is totally cold-processed without the use of additives or water.
  • the aluminium hydroxide has a final percentage from 1% to 50% by weight, even more preferably from 10% to 30%.
  • the alkali salt mixture has a final percentage from 50% to 99% by weight, even more preferably from 70% to 90%.
  • Alkali salts mean salts of alkali metal such as sodium, lithium, potassium, rubidium, cesium and francium.
  • the alkali metal salt is selected from sodium salts, potassium salts and lithium salts. Even more preferably it is a sodium salt, e.g. sodium chloride.
  • the melting flux of the present invention consists of aluminium hydroxide and sodium chloride.
  • said flux consists of aluminium hydroxide at a final concentration from 10% to 30% by weight, preferably of 20%, and sodium chloride at a final concentration from 70% to 90% by weight, preferably of 80%.
  • the melting flux components are mixed in advance and then prepared in a variety of formats, for example in pads which can be melted in the melt bath.
  • the melting flux is prepared in a solid physical form, preferably is assembled into pads.
  • Said pads have a weight from 5g to 30g, preferably from 10g to 20g, and a specific weight from 1g/cm 3 to 3.5g/cm 3 , preferably a specific weight from 1.5g/cm 3 to 3g/cm 3 .
  • the physical form of the pads is very advantageous for the gradual reaction of the product: in fact, powders and granules react very quickly, soon finishing the effect thereof, while pads prolong the effectiveness thereof over time.
  • the flux may contain further components adapted to aid the maintenance of the flux, the flux melting inside a furnace, the production of said flux in briquettes or bundles.
  • Said further components may be adjuvants, accelerators, preservatives, film-forming agents, thickeners, or further elements suited for metallurgical employments.
  • the melting flux is added in a closed chamber of a melting furnace to the metal to be melted, for example scrap and foundry returns.
  • Said melting flux is added to the melting furnace in a percentage from 0.025% to 0.2% with respect to the weight of the metal to be melted, preferably in a percentage from 0.05% to 0.1% with respect to the weight of the metal to be melted.
  • Said percentage by weight depends on the type of metal and the quality thereof.
  • the metal melting thus occurs in the presence of a limited amount of melting flux.
  • the recommended working temperature i.e. the flux melting temperature
  • 600°C preferably higher than 680°C based on the metal/s present together with the impurities.
  • the melting point of pure aluminium is 660°C, but in the presence of other alligated metals and impurities, it exceeds 680°C.
  • the melting furnace may be opened and the slagging may be performed by means of said mechanical shovel, because, by virtue of the reaction of the melting flux with the metal, a surface film is obtained, which avoids the combustion of the slag with the outside air.
  • the melting flux according to the present invention substantially reduces the flammability of the incandescent slag floating on the molten metal.
  • the molten metal may be poured into a second chamber, for example, by means of an internal duct which will remain clean because the slag has already been removed.
  • the employment of the melting flux is able to reduce melting drops which may occur inside a melting furnace or a double chamber furnace.
  • Another advantage is that the slag obtained at the end of the melting operation is particularly poor in metal and easily removable from the molten metal.
  • the final features of the metal obtained from the melting operation are therefore better due to the employment of said melting flux, as the slagging is better and the molten metal has a better degree of purity.
  • An additional advantage is that, if the melting is systematically employed in the melting furnace or in the double chamber furnace, said melting flux is adapted to keep the refractory walls of the melting furnace clean, thus avoiding the formation of metal oxides such as corundum.
  • a further advantage is that the melting flux has high wetting properties in solid metal, i.e. it dissolves very rapidly inside the bath for the metal melting.
  • said melting flux is adapted to slag aluminium and aluminium alloys, preferably aluminium alloys with a magnesium content lower than 2%, preferably lower than 1%, since magnesium is highly flammable.
  • the slag is particularly rich in metal oxides and impurities, and poor in aluminium.
  • the use of the melting flux for slagging and deoxidating aluminium and its alloys is particularly advantageous because it favors the melting at low temperature (between 670°C and 720°C) avoiding, or at least reducing, the aluminothermic reaction, and reducing oxides.
  • the following is a non-limiting embodiment of a melting flux in pads for the recovery of aluminium from scrap and foundry returns.
  • melting flux avoids the aluminothermic reaction of the product.
  • the slag is dry and poor in aluminium.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Analytical Chemistry (AREA)
  • Manufacture And Refinement Of Metals (AREA)

Description

  • The present invention relates to a melting flux for slagging and deoxidating molten aluminium and its alloys.
  • During metal melting processes in melting furnaces, one of the main aspects for obtaining a finished material with optimal features is the slagging of molten metal. Slagging is the process of eliminating residues and slag from the product being melted inside the furnace, in particular suspended oxides from metal.
  • Double chamber furnaces are known, in which metal scrap is melted and the slag produced by the melting operation is eliminated.
  • The metal is normally melted in a first closed chamber at over 700°C: at the end of the melting operation, a slag layer remains, floating on the molten metal bath.
  • Said slag comprises harmful metals, for example aluminium and magnesium which is highly flammable.
  • Said first chamber may not be opened, since the contact with the air would burn the highly flammable slag.
  • The molten metal is then necessarily poured into a second chamber by means of an internal duct.
  • Disadvantageously, the slag layer tends to obstruct said duct causing serious damage to the furnace, also limiting the slagging in said second chamber which requires conditions suitable for the opening.
  • JP-2004176095 describes a melting lime-base flux for slagging molten metal containing aluminium hydroxide.
  • US-3309196 discloses a melting flux for reduction of oxidized iron material, comprising alkali salt and aluminium oxide.
  • US-3650730 discloses a melting flux for removing impurities from aluminuim or aluminuim alloys, comprising a chloridizing agent.
  • It is the object of the present invention to achieve a melting flux which allows the slagging directly into the chamber where the metal melting occurs, in particular the melting of aluminium and its alloys.
  • It is another object to achieve a cost-effective melting flux, easy to be handled and transported, and not harmful.
  • According to the invention, such objects are achieved by a melting flux as described in claim 1.
  • These and other features of the present invention will become more apparent from the following detailed description of practical embodiments thereof.
  • A melting flux of the present invention is adapted to be employed in melting furnaces, in particular in double chamber furnaces.
  • Said melting flux is a compound comprising aluminium hydroxide and an alkali salt mixture, and is totally cold-processed without the use of additives or water.
  • Preferably, the aluminium hydroxide has a final percentage from 1% to 50% by weight, even more preferably from 10% to 30%.
  • Preferably, the alkali salt mixture has a final percentage from 50% to 99% by weight, even more preferably from 70% to 90%.
  • Alkali salts mean salts of alkali metal such as sodium, lithium, potassium, rubidium, cesium and francium. Preferably, the alkali metal salt is selected from sodium salts, potassium salts and lithium salts. Even more preferably it is a sodium salt, e.g. sodium chloride.
  • For example, the melting flux of the present invention consists of aluminium hydroxide and sodium chloride. In particular, said flux consists of aluminium hydroxide at a final concentration from 10% to 30% by weight, preferably of 20%, and sodium chloride at a final concentration from 70% to 90% by weight, preferably of 80%.
  • The melting flux components are mixed in advance and then prepared in a variety of formats, for example in pads which can be melted in the melt bath.
  • In particular, the melting flux is prepared in a solid physical form, preferably is assembled into pads. Said pads have a weight from 5g to 30g, preferably from 10g to 20g, and a specific weight from 1g/cm3 to 3.5g/cm3, preferably a specific weight from 1.5g/cm3 to 3g/cm3.
  • The physical form of the pads is very advantageous for the gradual reaction of the product: in fact, powders and granules react very quickly, soon finishing the effect thereof, while pads prolong the effectiveness thereof over time.
  • The flux may contain further components adapted to aid the maintenance of the flux, the flux melting inside a furnace, the production of said flux in briquettes or bundles. Said further components may be adjuvants, accelerators, preservatives, film-forming agents, thickeners, or further elements suited for metallurgical employments.
  • The use of said melting flux is highly simple and at the same time effective.
  • The melting flux is added in a closed chamber of a melting furnace to the metal to be melted, for example scrap and foundry returns.
  • Said melting flux is added to the melting furnace in a percentage from 0.025% to 0.2% with respect to the weight of the metal to be melted, preferably in a percentage from 0.05% to 0.1% with respect to the weight of the metal to be melted.
  • Said percentage by weight depends on the type of metal and the quality thereof.
  • The metal melting thus occurs in the presence of a limited amount of melting flux.
  • The recommended working temperature, i.e. the flux melting temperature, is higher than 600°C, preferably higher than 680°C based on the metal/s present together with the impurities. For example, the melting point of pure aluminium is 660°C, but in the presence of other alligated metals and impurities, it exceeds 680°C.
  • It is important that the flux melts also when the metal is in the molten phase, so as to guarantee an immediate effect.
  • When the metal is completely melted, it is necessary to wait that the metal slag floats on the molten metal, and then it is "slagged", i.e. the slag is removed from the surface of the molten metal by means of a mechanical shovel, for example.
  • Advantageously, the melting furnace may be opened and the slagging may be performed by means of said mechanical shovel, because, by virtue of the reaction of the melting flux with the metal, a surface film is obtained, which avoids the combustion of the slag with the outside air.
  • The melting flux according to the present invention substantially reduces the flammability of the incandescent slag floating on the molten metal.
  • Once the mechanical slagging has occurred, the molten metal may be poured into a second chamber, for example, by means of an internal duct which will remain clean because the slag has already been removed.
  • Advantageously, the employment of the melting flux is able to reduce melting drops which may occur inside a melting furnace or a double chamber furnace.
  • Another advantage is that the slag obtained at the end of the melting operation is particularly poor in metal and easily removable from the molten metal.
  • The final features of the metal obtained from the melting operation are therefore better due to the employment of said melting flux, as the slagging is better and the molten metal has a better degree of purity.
  • An additional advantage is that, if the melting is systematically employed in the melting furnace or in the double chamber furnace, said melting flux is adapted to keep the refractory walls of the melting furnace clean, thus avoiding the formation of metal oxides such as corundum.
  • A further advantage is that the melting flux has high wetting properties in solid metal, i.e. it dissolves very rapidly inside the bath for the metal melting.
  • In particular, said melting flux is adapted to slag aluminium and aluminium alloys, preferably aluminium alloys with a magnesium content lower than 2%, preferably lower than 1%, since magnesium is highly flammable. The slag is particularly rich in metal oxides and impurities, and poor in aluminium.
  • The use of the melting flux for slagging and deoxidating aluminium and its alloys is particularly advantageous because it favors the melting at low temperature (between 670°C and 720°C) avoiding, or at least reducing, the aluminothermic reaction, and reducing oxides.
  • The physical form in pads, together with other chemical-physical properties due to the salt mixture, allows to benefit from further advantages:
    • there are no melting flux losses due to the sudden thermal expansion, with consequent emission of powders in the internal environment of the furnace, allowing to avoid melting flux losses by means of the suction of suction and depowdering systems which are mandatorily installed with the melting furnaces; as a result, reduced consumption of product and higher yields are achieved;
    • each single pad contains all the different components provided for in the chemical formulation, maintaining the proportions and percentages provided for; as a result, every single point of reaction where the pad melts, creates the same chemical reaction conditions between the oxidized surface of the solid charge and the environmental condition (physical-chemical balance between solid phase and liquid phase); this ensures a very high microlocalized yield, since it is not altered by false conditions; the micro set is therefore 100%, i.e., reaction and effect homogeneity.
  • The following is a non-limiting embodiment of a melting flux in pads for the recovery of aluminium from scrap and foundry returns.
  • 1.2 kg of melting flux, in small pads of 13 g and composed 30% of aluminium hydroxide and 70% of alkali salts, is added to about 1500 kg of aluminium scrap and the whole is placed in a furnace operating at a temperature of approximately 680°C.
  • Once the mixture of scrap and flux is completely molten, the slag is removed from the surface of the molten metal.
  • The process described as melting flux according to the present invention avoids the aluminothermic reaction of the product.
  • Advantageously, the slag is dry and poor in aluminium.

Claims (12)

  1. A melting flux for removing slag of molten aluminium and molten aluminium alloys in melting furnaces, comprising an alkali salt mixture, characterized in that it further comprises aluminium hydroxide, wherein the aluminium hydroxide has a final concentration from 1% to 50% by weight, and wherein the alkali salt mixture has a final concentration from 50% to 99% by weight.
  2. A flux according to claim 1, characterized in that the aluminium hydroxide has a final concentration from 10% to 30% by weight.
  3. A flux according to claims 1, characterized in that the alkali salt mixture has a final concentration from 70% to 90% by weight.
  4. A flux according to any one of the preceding claims, characterized in that the alkali salt mixture comprises salts selected from a group comprising sodium salts, potassium salts and lithium salts.
  5. A flux according to claim 4, characterized in that it comprises sodium chloride.
  6. A flux according to any one of the preceding claims, characterized in that it is prepared in pads.
  7. A flux according to claim 6, characterized in that said pads have each a weight from 5g to 30g, preferably from 10g to 20g.
  8. A flux according to claims 6 and 7, characterized in that the pads have a specific weight from 1g/cm3 to 3.5g/cm3, preferably a specific weight from 1.5g/cm3 to 3g/cm3.
  9. A flux according to any one of the preceding claims, characterized in that it has a working temperature higher than 600°C, preferably higher than 680°C.
  10. A flux according to any one of the preceding claims, characterized in that said melting flux is added to the melting furnace in a percentage from 0.025% to 0.2% with respect to the weight of the metal to be melted, preferably in a percentage from 0.05% to 0.1% with respect to the weight of the metal to be melted.
  11. A flux according to any one of the preceding claims, characterized in that said melting flux is adapted to slag aluminium alloys with a magnesium content lower than 2%, preferably lower than 1%.
  12. A flux according to claim 11, characterized in that it has a working temperature of between 670°C and 720°C.
EP18181322.1A 2017-07-04 2018-07-03 Melting flux for slagging and deoxidating molten metal Active EP3425071B1 (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT102017000074924A IT201700074924A1 (en) 2017-07-04 2017-07-04 Flux for melting the molten metal.

Publications (2)

Publication Number Publication Date
EP3425071A1 EP3425071A1 (en) 2019-01-09
EP3425071B1 true EP3425071B1 (en) 2020-12-16

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IT (1) IT201700074924A1 (en)

Family Cites Families (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3309196A (en) * 1964-10-28 1967-03-14 Wyandotte Chemicals Corp Fluxing agent
ES365009A1 (en) * 1968-03-21 1971-01-16 Alloys And Chemical Corp Purification of aluminium
US4126453A (en) * 1976-05-17 1978-11-21 Esm, Inc. Composition for a fluidizing flux in the production of iron and steel
US4261746A (en) * 1979-10-30 1981-04-14 American Can Company Flux
JP4089815B2 (en) * 2002-11-26 2008-05-28 大阪鋼灰株式会社 Lime-based flux for refining
CA2668473C (en) * 2009-06-08 2014-08-19 Pyrotek, Inc. Use of a binary salt flux of nacl and mgcl2 for the purification of aluminum or aluminum alloys, and method thereof

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
None *

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Publication number Publication date
IT201700074924A1 (en) 2019-01-04
EP3425071A1 (en) 2019-01-09

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