GB2024046A - Process for the production of a granular synthetic slag for continuous steel casting - Google Patents

Process for the production of a granular synthetic slag for continuous steel casting Download PDF

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Publication number
GB2024046A
GB2024046A GB7921484A GB7921484A GB2024046A GB 2024046 A GB2024046 A GB 2024046A GB 7921484 A GB7921484 A GB 7921484A GB 7921484 A GB7921484 A GB 7921484A GB 2024046 A GB2024046 A GB 2024046A
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slag
granules
steel
carbon
production
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GB2024046B (en
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KEMPRO ITALIANA SpA
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KEMPRO ITALIANA SpA
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22DCASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D11/00Continuous casting of metals, i.e. casting in indefinite lengths
    • B22D11/10Supplying or treating molten metal
    • B22D11/11Treating the molten metal
    • B22D11/111Treating the molten metal by using protecting powders

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Continuous Casting (AREA)
  • Treatment Of Steel In Its Molten State (AREA)

Abstract

Process for the production of a synthetic slag in the form of hollow spheroidal granules for continuous steel casting, wherein the starting material is milled to a high grade of fineness until a homogeneous mush or slurry is obtained, which is atomized in an atomization tower in a stream of hot air, the product obtained is calcined and the calcined material is subsequently coated with a powdered carbon-containing material, such as powdered carbon or graphite.

Description

SPECIFICATION Process for the production of a granular synthetic slag for continuous steel casting This invention relates to a synthetic slag for casting, in particular for continuous steel casting.
More particularly, such a process refers to the production of a synthetic slag in the form of hollow spheroidal granules, obtained from a casting powder and from proper agglomerative bases.
The function of slag in steel treatment is that of eliminating impurities from the metal in the form of a fusible phase clearly separable from the metallic phase.
Because the metal impurities are difficult to fuse in order to produce the slag it is necessary to use additives which, by virtue of chemical reaction, render them fusible at a temperature far below that of the melting of steel.
Slag also has certain lubricating properties which are important when the slag comes between the flat blooms or billets and the molds in continuous casting, thus avoiding damages to the walls of the mold and the surfaces of the flat blooms and billets in their downward movement.
The slag must maintain a proper viscosity when the steel solidifies in its downward movement.
The slag commonly used for steel casting is essentially a synthetic slag obtained by mixtures of various oxides, carbonates and metallic fluorides as well as carbon or graphite in the form of fine powder. These slags when they come into contact with the surface of the liquid steel, melt and cover the liquid surface, with the twofold purpose of slowing down the oxidation of the steel directly exposed to the air and insulating against upward heat loss by radiation.
As mentioned above the slags help to dissolve the various oxides in the form of solid fragments which are unavoidably present in suspension in the melted steel as impurities and which the subsequent solidification of the steel could be incorporated in it, causing significant defects.
Synthetic slags are generally known in the trade as mixtures of powdery components, of glassy masses granulated by milling, and of hollow spheroidal granules (spherulites).
The powder mixtures are constituted by calcium and aluminium complex silicates, sodium and calcium fluorides of mineral origin, or by by-products of the cement industry or of iron metallurgy, or by coal ashes, or by debris of marble quarries.
These mixtures obtained by simple mechanical mixing under dry conditions, have a very low production cost, but have some serious drawbacks, for example, the components must be in the form of very fine powder, for example with dimensions lower than 50 microns, so as to have uniform chemical composition and physical properties through the whole mass; this causes significant dust production at the moment of use in the steel plant; In addition segregation of components may occur during transportation, because of the difference in their specific gravity, with consequent loss of uniformity in the composition, especially if the water content is reduced to a minimum, as is usually the case; Furthermore, the greater part of these types of powders contain a certain percentage of carbonates which, at the temperature of melted steel decompose, liberating CO2 and, because of the strongly reducing environment, CO, with development of flames and smoke.
The second form of synthetic slags used in the trade consists of a glassy mass granulated by milling.
This mass is obtained by melting in the conventional blowing furnaces the proper components, so that the glass obtained has the required content of oxides, fluorides and silicates of Ca, Al, Fe, Na, Li and B.
This glassy mass is then abruptly cooled by casting it in cool water so as to make it break down into granules of some mm of size; these granules are then milled until they reach dimensions of some hundreds of microns and finally they are graphitized by mixing with powdered graphite or carbon.
There are, however, some drawbacks in this method, for example the reagents may react during the melting with the refractory material of the furnace.
In addition, it is extremely difficult to obtain uniformity in the composition, and graphite and carbon do not adhere adequately to the glass granules, and therefore the granules may sinter before melting during the addition to the melted steel, thus compromising the uniform spreading of the granules and increasing the danger of solid inclusions into the steel. The production process of these glassy masses is furthermore expensive.
The third known form of powder for continuous casting is constituted by hollow spheroidal granules, the so-called spherulites.
The spherulites allow a favourable process of scorification, have good insulating properties and a limited tendency to pulverize.
They are present in small amounts, from 0.5 to 0.6% by weight, in coal ashes.
A process is disclosed in German Auslegeschrift No 1558225, for obtaining a casting powder constituted only by spherulite, or by a mixture of spherulite and coal ashes, with a major percentage of spherulite, by flotation performed on natural coal ash.
This process is very expensive because it requires the treatment of huge amounts of ashes on account of the low spherulite content of natural ashes.
In order to obviate this drawback, German Auslegeschrift No 2614957 indicates a production of synthetic spherulites, by means of atomization and subsequent expansion of a mixture wherein the components of the casting powder and a swelling agent are dispersed. The spherulites thus obtained have a granulometry greater than 60 microns and obviate the drawbacks caused by the lack of uniformity in composition and by the tendency to pulverize during use.
However, these spherulites have the drawback that they contain carbonates, which at the moment of use on the surface of the melted steel, decompose liberating CO2 and as before mentioned develop flames and smoke.
Another drawback of the spherulites obtained by the above described process is the rather high water content, that is variable within the range of from 1 to 5% by weight; this constitutes a serious defect and may even preclude its use in the casting of steel sensitive to hydrogen embrittlement.
This invention provides a process for the production of a synthetic slag in the form of hollow spheroidal granules for use in continuous steel casting, which process comprises milling the starting material for the slag to a high grade of fineness to produce a homogeneous slurry or mush, atomizing the slurry in a stream of hot air, calcining the product obtained and coating the calcined material with a powdered carbon-containing material.
The invention also provides a synthetic slag for continuous steel casting, in the form of hollow spheroidal calcined granules, having a coating of a carbon-containing material and a method for the continuous production of steel, wherein such slag is used.
The material in granules according to the present invention for covering the surface of the melted steel in the mold, besides the advantages of the spherulites themselves, such as a high thermal insulating capacity, reduced tendency to pulverize and uniformity of composition, presents further advantages.
The main advantage is due to the fact that when this material melts and spreads on the surface of melted steel it does not produce carbon dioxide or other gases, neither does it develop flames.
Another advantage is due to the fact that when the material is poured on the surface of the melted steel, it does not sinter before melting, thus avoiding the agglomeration of the particles and avoiding lack of uniformity of spreading, and the danger of inclusions within the steel.
Another advantage of the process is due to the fact that the obtained material is free from water, thus avoiding any danger of hydrogen embrittlement.
Finally, because of the speed of spreading of the granular material, its application can be effected by mechanical means, so as to reduce substantially the risk to the personnel working at the mold of breathing in toxic gases liberated.
The base material for the production of the casting powder, constituted by hollow spheroidal granules, may be prepared from any composition of oxides and fluorides of Ca, Si, Al, Fe, B, Na and Li within the conventional limits for use in continuous steel casting.
A further advantage of the process is due to the possibility of fixing and reliably controlling the chemical composition of the synthetic slag, the more opportune viscosity and lubricating power, the solvent properties towards the solid slags, and the protective effect against surface oxidation.
The improvement in the behaviour of the synthetic slag, according to the present invention, allows for the attainment of a decrease in the surface and internal defects of the flat blooms and of the billets produced with this material and thus to reduce the percentage of waste.
The production process of the invention may be carried out by mixing the ingredients starting from a granular form having dimensions of some millimeters and milling until a high grade of fineness is reached.
At the end of the milling, the product is atomized in a stream of hot air and this may be carried out by conventional techniques, for example by spraying through nozzles in a drying tower. The temperature of the hot air is preferably between 300"C and 600"C.
At the outlet from the drying room or tower, the material falls in the form of small hollow spheres having dimensions ranging from about 100 to about 500 microns, with a very low content of powdery fines.
After drying in the atomization tower the material may still contain water in a percentage ranging between 1 and 5%, as well as CO2 and perhaps other gases.
To eliminate CO2, the hollow spheroidal granules are submitted to a rapid calcination, bringing them for a few moments to such a temperature as to ensure the decomposition of the carbonates, but not the sintering of the granules. The maximum percentage of water and eventually other gases are eliminated besides CO2.
This operation may be performed in a rotating subhorizontal kiln of the type analogous to that used for cement banking or in an upright shaft furnace similar to that used for pre-heating the raw materials intended to be roasted in a rotary cement kiln. The maximum calcination temperature may be from 300"C to 1000"C and will vary depending on the starting and final composition; in general the temperature of the hot gases used for the calcination is such that at the outlet of the kiln, the sensible heat of the gases may still be used by mixing the calcination gases with the hot gases entering the atomization chamber, thus obtaining a saving in energy.
A further operation is performed after the calcination and consists in the coating of the granules with a carbon-containing material, for example powdered carbon or graphite.
The purpose of this coating is essentially to prevent sintering of the granules of the material when they are applied to the surface of the melted steel. In fact, although the covering layer which is in contact with steel is melted, the upper layers may be at a softening temperature, which in the absence of the carbon coating favours sintering and thus the formation of semisolid agglomerates.
The carbonous coating, in particular if the graphite is of the proper quality, such that it has good adhesion to the calcined granules, prevents the latter from adhering to each other and sintering at the softening temperature.
Silvery graphite with a high carbon content has been found to be particularly efficient.
Preferably the amount of said graphite is from 3-10% by weight of the entire compositions.
EXAMPLE This Example shows the compositions of hollow spheroidal granules produced according to German Auslegeschrift No 2614957 and according to two embodiments of the present invention (Sample 1 and Sample 2).
Chemical analysis Scorialit SPH2 Product according to the (DSA 2614957) present invention Sample 1 Sample 2 SiO2 32,5-35,5% 35,8% 29,6% CaO/MgO 32,5-35,5% 30,1% 30,7% Awl203 7,0-10,0% 8,30% 3,2% NaO/K2O 3,0-5,0% 4,4% 11,0% Fe203 1,0% 0,95% 0,28% C 8,5-9,5% 7,57% 8,23% CO2 5,5-7,5% Not determinable F 4,0-5,0% 5,5% 3,3% H2O6oo.c 0,8% 0, 1% 0,2% From the table it is clear that the granules obtained according to the invention have a negligible CO2 content and a very low H2O content, as compared with Scorialit SPH2.
The present invention has been described with particular reference to a specific embodiment thereof, but variations of modifications may be introduced therein.

Claims (15)

1. A process for the production of a synthetic slag in the form of hollow spheroidal granules, for use in continuous steel casting, which process comprises milling the starting materials for the slag to a high grade of fineness to produce a homogeneous slurry or mush atomizing the slurry in a stream of hot air, calcining the product obtained and coating the calcined material with a powdered carbon-containing material.
2. A process as claimed in claim 1, wherein the calcination is performed at a temperature of from 300 to 1000"C.
3. A process as claimed in claim 1 or claim 2, wherein the carbon-containing material is finely powdered carbon.
4. A process as claimed in claim 3, wherein the powdered carbon is silvery graphite.
5. A process as claimed in claim 4, wherein the amount of silvery graphite is such as to constitute from 3 to 10% by weight of the slag.
6. A process as claimed in any one of the preceding claims, wherein the starting material comprises oxides or fluorides of one or more of Ca, Si, Al, Fe, B, Na and Li.
7. A process as claimed in any one of the preceding claims, wherein the hollow spheroidal granules have a diameter of from 100 to 500 microns.
8. A process for the production of a synthetic granular slag for continuous steel casting, substantially as hereinbefore described.
9. A synthetic slag for continuous steel casting in the form of hollow spheroidal calcined granules, having a coating of a carbon-containing material.
10. A slag as claimed in claim 9, wherein the carbon-containing material is silvery graphite.
11. A slag as claimed in claim 9 or claim 10, comprising at least one oxide or fluoride of Ca, Si, Al, Fe, B, Na or Si.
1 2. A slag as claimed in any one of claims 9 to 11, wherein the granules have a diameter of from 100 to 500 microns.
1 3. A slag as claimed in any one of claims 9 to 12, when produced by a method as claimed in any one of claims 1 to 8.
14. A method for the continuous casting of steel, which method comprises adding to the molten steel a synthetic slag as claimed in any one of claims 1 to 1 3.
15. Steel produced by a process as claimed in claim 14.
GB7921484A 1978-06-28 1979-06-20 Process for the production of a granular synthetic slag for continuous steel casting Expired GB2024046B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT50075/78A IT1105042B (en) 1978-06-28 1978-06-28 PROCEDURE FOR THE PRODUCTION OF A SYNTHETIC GRANULAR SLAG FOR THE CONTINUOUS CASTING OF STEEL AND ITS PRODUCT OBTAINED

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GB2024046A true GB2024046A (en) 1980-01-09
GB2024046B GB2024046B (en) 1982-06-09

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BE (1) BE877155A (en)
FR (1) FR2429840A1 (en)
GB (1) GB2024046B (en)
IT (1) IT1105042B (en)
NL (1) NL7904911A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0018633A2 (en) * 1979-05-02 1980-11-12 Wacker-Chemie GmbH Casting flux for the continuous casting of steel
EP0065230A1 (en) * 1981-05-14 1982-11-24 Mobay Chemical Corporation A method of producing a slagging composition for the continuous casting of steel
EP0137734A2 (en) * 1983-09-22 1985-04-17 Foseco International Limited Fluxes for casting metals

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1558225C3 (en) * 1967-02-04 1973-12-06 Eitel, Hans-Joachim, Dipl.-Ing., 4330 Muelheim Use of Spharohth or a mixture of fly ash with an addition of Spharohth for casting powder for mold casting
DE2345921A1 (en) * 1973-09-12 1975-03-20 Solint Consulting Establishmen Heat-insulating cover for molten metals - using a granular with the same compsn. as the lining of the vessel
DE2614957C3 (en) * 1976-04-07 1978-11-02 Hans Joachim Dipl.-Ing. Eitel Process for the production of casting powder
BE849022A (en) * 1976-12-02 1977-06-02 IMPROVED COVERING POWDER FOR CONTINUOUS METAL CASTING

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0018633A2 (en) * 1979-05-02 1980-11-12 Wacker-Chemie GmbH Casting flux for the continuous casting of steel
EP0018633A3 (en) * 1979-05-02 1981-08-26 Wacker-Chemie Gmbh Casting flux for the continuous casting of steel
EP0065230A1 (en) * 1981-05-14 1982-11-24 Mobay Chemical Corporation A method of producing a slagging composition for the continuous casting of steel
EP0137734A2 (en) * 1983-09-22 1985-04-17 Foseco International Limited Fluxes for casting metals
EP0137734A3 (en) * 1983-09-22 1986-01-22 Foseco International Limited Fluxes for casting metals

Also Published As

Publication number Publication date
GB2024046B (en) 1982-06-09
NL7904911A (en) 1980-01-03
BE877155A (en) 1979-10-15
IT1105042B (en) 1985-10-28
IT7850075A0 (en) 1978-06-28
FR2429840A1 (en) 1980-01-25

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