Metal Load Calculation for Alloys
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ScribdTranslationsMetal Load Calculation for Alloys
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The metal charge for loading the furnace is
normally composed of the following types of
raw material:
Return
Steel scrap
Cast iron scrap
Pig iron
Alloys of iron
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To carry out the preparation of a metal alloy
it is necessary initially:
1. stipulate the range of chemical composition desired
reach in the rough piece
2. Verify the chemical composition present in the
raw materials and available ferroalloys
3. Check the values of losses and gains of
elements in the melting furnace.
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1. Establish the range of Chemical composition:
Desired league: FC 150 Developed in induction oven
C = 3.20 to 3.50%
If = 2.30 to 2.50%
Mn = 0.40 to 0.50%
S = < 0.10%
P = < 0.10%
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2- Chemical composition of the available raw material:
RAW MATERIAL%
CHEMICAL ELEMENT
RETURN OF CAST IRON SCRAP
C 3.40 0.80 4.25
Yes 2.10 ["1.20","2.30"]
Mn 0.20 0,75 0,50
P 0.03 0.01 0.02
S 0.02 0.01 0.02
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3- Check the values of losses and gains of the elements
in the melting furnace:
TYPE OF Chemical Elements
oven SILICON CARBON MANGANESE SULFUR PHOSPHORUS
INDUCTION LOSS 5% LOSS 10% LOSS
NULL 10%NULL
CUBILÔNULO LOSS 10% LOSS 15% GAIN 40% NULL
The oil LOSS 10% LOSS 15% LOSS 20% NULL NULL
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Verification of the chemical composition, Let's calculate one
load with:
50% Return + 10% steel scrap + 40% pig iron.
RAW MATERIAL%
C.Q OBTAINED
CHEMICAL ELEMENT RETURN STEEL SCRAP GUSA
50% 10% 40% 100%
C 1.70 0.08 1.70 3.48
Yes 1.05 0.12 0.92 2.09
Mn 0.10 0.075 0.25 0.43
P 0.015 0,001 0,0084 0.024
S 0.010 0,0009 0,006 0.0169
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Chemical composition verification:
ELEMENT RAW MATERIAL
50% in mathematics is the same as: 50
CHEMICAL RETURN
100
C 3.40%
If we solve this division, we will get = 0.5
If 2.10%
Mn 0.20%
Finding the values of the chemical elements in
P 0.03% composition of the load:
S 0.02%
MATERIAL 0.5 x % C in the return = how much it will add to the element
FIRST% in the chemical composition
CHEMICAL ELEMENT
RETURN 0,5 x 3,40 = 1,70 %
50%
0.5 x 2.10 = 1.05%
C 1.70
0.5 x 0.20 = 0.10%
Yes 1.05
Mn 0.10 0.5 x 0.03 = 0.015%
P 0.015 0,5 x 0,02= 0,010%
S 0.010
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Verification of chemical composition after losses and gains
since the preparation will be in an induction oven:
Desired C.Q
C = 3.20 to 3.50%
C.Q COMPOSITION Yes = 2.30 to 2.50%
ELEMENT RAW MATERIAL% LOSSES AND
OBTAINED CHEMISTRY Mn = 0.40 to 0.50%
CHEMICAL RETURN S. OF CAST IRON GAINS S = < 0.10%
OVEN
50% 10% 40% 100% P= < 0.10%
C 1.70 0,08 1,70 3.48 -5% 3.30%
Yes 1.05 0.12 0.92 2.09 -10% 1.88%
Mn 0.10 0.075 0.25 0.43 -10% 0.38%
P 0.015 ["0.001","0.0084"] 0.024 NULL 0.024 %
S 0.010 0,0009 0,006 0.0169 NULL 0.0169 %
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Verification of the chemical composition after
additions/corrections and treatments:
RAW MATERIAL% C.Q LOSSES
ELEMENT C. Q. ADDITION TREAT. C. Q.
CAST IRON RETURN S. OBTAINED E
CHEMICAL OVEN BATH INOC. FINAL
50% 10% 40% 100% GAINS
C 1.70% 0.08% 1,70% 3,48% -5% 3.30% 3.30%
If 1.05% 0.12% 0,92% 2,09% -10% 1.88% 0.22% 0.3% 2.40%
Mn 0.10% ["0.075% 0.25% 0.425% -10%"] 0.38% 0.07% 0.45%
P 0.015% ["0.001%","0.008%","0.024%","NULL","0.024%"] 0.024%
S 0.010% 0,0009% 0,006% 0,017% NULO 0,0169 % 0.017%
Desired C.Q
C = 3.20 to 3.50%
If = 2.30 to 2.50%
Mn = 0,40 a 0,50%
S = < 0.10%
P= < 0.10%
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Calculation of Correction/Additive of the chemical composition:
Increase
Do
Element%
= Quantity of
Element
in the league % X
Yield of
Element
treatment %
no
X Amount of
league to be
added %
Ex: ↑0.22% Si = 0.75 x 0.90 x alloy quantity to add %
↑0.22 %Si = 0.67 xQ of alloy to be added % To know the weight amount to be added.
League Q to add % = 0.22 just execute the following equation:
0.67 0.33 X Weight of metal to be treated in kg.
100
League Q to add % =0.33 Example to correct 1000kg of metal:
0.33 X 1000 kg = 3.3 Kg of silicon iron 75 p/correction
100
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Most commonly used practical formula: Practicing yield table
Material Yield
% desired to add x weight of metal in the furnace Graphite 90%
Material yield Fesi 75 75%
FEMn 70%
Let's do an example of addition Cu 100%
silicon, my silicon in the oven is at 1.65% Sn 100%
my desired percentage is 2.0%, so I have FECr 50%
what to add 0.35% to reach the content of Pirita (S) 30%
FEMo 50%
silicon at 2.0%
0.35X1000KG = 4.66 kg of FeSi 75 for furnace correction
75
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Dilution of Chemical Composition Carbon Correction:
formula:
PC= PFx (%CI- %CF) where
(%CI- %CC)
PCweight of correction (kg).
PFoven weight (oven capacity) (kg).
%CIinitial carbon percentage (% of carbon in the metal).
%CFfinal carbon percentage (% of carbon desired).
%CC percentage of carbon in the correction load (steel, return, pig iron, etc).
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Note that the weight found for the correction should be the weight taken from the oven.
You have the furnace full, 800 kg of cast iron with 3.6% carbon. You want to
reaching 3.3% carbon and has steel with 0.12% carbon for correction.
PC= 800 x (3.6-3.3)
(3.6–0.12)
Pc = 68.97 = 69 kg
You will need to use 69 kg of steel, and for that, you will have to cast 69 kg of the molten iron that is in the
oven.
The levels of the other elements (Si, Mn, and S) will be altered, usually downwards.
you will have to make additions to correct. Use the formula for addition.