Cast iron production from sponge iron : final technical and financial report
Date
1993
Journal Title
Journal ISSN
Volume Title
Publisher
Central Metallurgical Research and Development Institute (CMRDI), Cairo, EG
Abstract
The foundry industry in Egypt faces nowadays serious difficulties in
securing the proper raw materials, especially those needed to produce molten
metal. Both foundry grade pig iron and special types of pig iron; needed for
ductile cast iron production are imported. In the meantime, classified steel
scrap of the proper qualities is becoming a real scarcity.
This report discusses the results obtained, on pilot scale, when using
locally produced sponge iron - or directly reduced iron (DRI) as a main charge
constituent in both induction furnaces as well as cupolas.
that melting of sponge iron in both of furnaces
It has been shown
is technically and
economically feasible. The pilot findings of this research gave much of the
background needed to begin commercial applications in three Egyptian
foundries.
Sponge iron was utilized to produce either high purity pig iron in
induction furnace, and that HPPI was later used for the production of ductile
iron; or to directly produce ductile iron castings when added to a molten pool
of Egyptian pig iron, steel scrap or foundry grade pig iron. On the pilot scale
no difficulties were encountered in removal of excessive amounts of slag
formed during melting - the influence on lining life was as well insignificant.
On the other hand, the life time of lining of commercial scale induction
furnaces was reduced by about 25% when using up to 30% sponge iron in the
charge. This extra cost was, however, counterbalanced by the price
difference of raw materials and the production cost of one ton of HPPI was
still about 30% cheaper in favour of charges containing sponge iron...
Description
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IDRC Final Report
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Text
Keywords
METALLURGY, EGYPT, FOUNDRIES, IRON, SPONGE IRON, DIRECT REDUCTION, FRACTURE, IRON AND STEEL INDUSTRY, PRODUCTION COSTS, PRODUCTION TECHNIQUES, MIDREX, INDUSTRIAL PROCESSES, INDUSTRIAL RESEARCH, INDUSTRIAL DESIGN