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pgpanikkar
Active Contributor

Join Date: Dec 2007
Posts: 24

induction furnace steel melting

01/04/2009 11:53 AM

Dear Sirs, In an induction steel melting core less furnace of 9Tons capacity near Hyderabad (India) ,the sponge iron fines of about 70%Fe is used along with Shredded scraps I.S.R.I 211(imported). The Al2O3 in the sponge iron was found around 6% to 7.5 and sulphur around 0.07 %depending on the sources of supply .

The slag is viscous and there is about 25-35%Fe in the slag which is removed manually from the open furnace.The power consumption is about 750KWH/T.We have tried 0.5 Kg of silicon carbide mixed with sponge iron fines in one heat and the Fe in slag is reduced to around 2% .

When silicon carbide was added along with steel scraps Fe in slag increased by 2%. We get about 7.5 tons to 8.3 tons of steel only from one heat.

Can any body give me some tips to

a)Reduce power consumption ?

b) To reduce Fe loss in slag

c)To make slag fuild so that slag metal separation shall be easier.

d)I am yet to get a supplier for calcium silicide at Hyderabad.Can any body suggest a reliable supplier and tell me the effect of calcium silicide if added.

There is not much scope to cover the furnace top as charging and removal of slag from furnace is to be carried out.

Regards,

PGPanikkar

pgpanikkar@rediffmail.com
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Milo
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Join Date: Jul 2006
Location: "Dancing over the abyss."
Posts: 4884
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#1

Re: induction furnace steel melting

01/04/2009 5:29 PM

What is your slag basicity?

http://www.springerlink.com/content/g3k326wtw32k5168/

Its all here.

You need to have chemistry capabilities if you are going to be a competent melter.

milo

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Panikkar
Associate

Join Date: Dec 2007
Location: secunderabad(India)
Posts: 37
#2
In reply to #1

Re: induction furnace steel melting

01/05/2009 7:16 AM

Tha analysis of one of the slag is as follows

Sio2-23.5%

AL2O3-0.20%

MnO2-19.78

S-0.10%

P-0.028%

Fe 43.86%

I have introduced silicon carbide one Kg/heat and I got results as below

Time of heat 2Hr 35minutes

Tonnage 8.874 KWH 783/Ton,Fein slag before addition of SiC33.6,Fe in slag after addition of Silicon carbide 26.8

Could you help me further? You can see that there is loss of Mn and and Fe in slag which is to be controlled as Ferro -silicon is also costly

Regards,

PGPanikkar

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 chartered engineer with experience of 44years in the primary zones of iron making areas like BF,Sinterplant, raw material handling in India and abroad
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Milo
Guru

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Location: "Dancing over the abyss."
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#3
In reply to #2

Re: induction furnace steel melting

01/07/2009 10:53 PM

did you read the springerlink paper? did you calculate the basicity?

milo

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Panikkar
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Join Date: Dec 2007
Location: secunderabad(India)
Posts: 37
#4
In reply to #3

Re: induction furnace steel melting

01/08/2009 8:27 AM

Dear Sir,

1.What we have is induction furnace with acid refractory. Hence we are unable to increase the basicity of the slag.What I have done is to introduce mixing of Silicon carbide about 2 Kg/ heat along with the sponge iron fines. I get a positive result as the Fe content of slag has reduced remarkably and fluidity increased.But more things are to be done.The client does not have facility to check the Alumina in the sponge iron .I have requested to get the input sponge iron fines analysed for alumina silica etc also.Now they are doing only Fe,carbon etc only.

Perhaps What you speak is more applicable for a blast furnace slag where you can control making slag basic.

2. I wish to humbly inform you that I have experience in iron making areas like sinter plants,Blast furnace etc and I am aware of the terms Basicity, slag fluidity etc.

3. Sorry that the springer paper I could not read as I was busy else where. I shall revert after I read the paper.Thank you for the reply

Regards

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 chartered engineer with experience of 44years in the primary zones of iron making areas like BF,Sinterplant, raw material handling in India and abroad
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Milo
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#5
In reply to #4

Re: induction furnace steel melting

01/08/2009 9:38 AM

Acid refractory takes me out of the picture. Good luck.

milo

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Anonymous Poster
#6
In reply to #2

Re: induction furnace steel melting

12/14/2009 1:32 AM

Dear sir,

If you found river sand in place of Ferro Silicon , you may save your cost & get same result.

Hardik
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Milo
Guru

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Location: "Dancing over the abyss."
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#7
In reply to #6

Re: induction furnace steel melting

12/14/2009 10:08 AM

Oxidation state of river sand is?

milo

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Steelmaker
Participant

Join Date: May 2010
Posts: 2
#9
In reply to #6

Re: induction furnace steel melting

05/14/2010 5:09 AM

Fail to understand, how river sand can repalce FeSi?

RKB
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sauravjain
Commentator

Join Date: May 2008
Posts: 64
#11
In reply to #2

Re: induction furnace steel melting

02/25/2011 2:58 AM

Can you suggest us any supplier preferably in west bengal for silicon carbide to be use in induction furnace.?

thanks and regards,

Saurav Jain.
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Anonymous Poster
#8

Re: induction furnace steel melting

05/14/2010 4:41 AM

Dear Mr Pannikar

You may get the ENERGY AUDIT of your IF done by NISST to reduce power consumption. They are very exerienced in the areas of all ferrous metallury processes. During the audit programme, you can get your persons shop floor training and solve all qulity and cost problems including recovery of Fe from slag.

Contact them at nisst@dataone.in

A well wisher
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Steelmaker
Participant

Join Date: May 2010
Posts: 2
#10

Re: induction furnace steel melting

05/14/2010 5:13 AM

Dear Mr Panikkar

Visit the site of NISST and contact them at nisst@dataone.in. They are very experienced in all ferrous metallugy processes. They can conduct ENERGY AUDIT of your plant and bring down energy consumption. They can also train your shop floor personnel and improve quality of steel product.

Steelmaker
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Govind Rao
Power-User
India - Member - New Member

Join Date: Jan 2009
Posts: 114
#12

Re: induction furnace steel melting

04/26/2014 3:13 AM

Dear Mr. Panniker,

Just a wild thought.....Try Silicon Carbide broken grinding wheels for the addition. These are available from Grinding Wheel manufacturers as rejects
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Govind Rao
Power-User
India - Member - New Member

Join Date: Jan 2009
Posts: 114
#13

Re: induction furnace steel melting

10/14/2014 6:14 AM

Dear Mr. Panniker,

Could you tell me as to how to avoid "Burning Loss" as it is put in local language. We are facing an 16% burning loss in melting.

Thanks ,

Rao
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Anonymous Poster (2); Govind Rao (2); Milo (4); Panikkar (2); sauravjain (1); Steelmaker (2)

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