Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking

Abstract

No problem with the melting of new carbon-free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon-free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life (~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron (contain 5% wax according to Jaleel waxing process) according to HYL costs system.

The Analysis of Slag Characteristics at VSB Eaf Consteel® Charging Hot Metal and the Influence on Refractory Performance

“…Controlling the chemical composition and solid fraction of EAF slags (a CaO-SiO2-MgO-FeO-(Al2O3)-P2O5 oxide system) are of utmost importance to improve foaming practice, protecting the arc and avoiding excessive consumption of the sidewall refractories due to chemical erosion [1,2].…”