The metallurgical outcomes of our pure Calcium wire are superior to those of conventional cored steel wires produced using welded sheath techniques. This is due to a much lower amount of Calcium (2- 4 times less) being needed to achieve similar metallurgical outcomes, allowing steelmakers to save significant amounts on their Calcium treatment.
This outstanding performance is due to the patented extruded coating of our calcium cored cable. This unique sheath ensures that the calcium is hermetically encapsulated and does not evaporate into the molten steel. Calcium is able to remain in the molten metal for a longer period of time, increasing the Calcium yield. This results in less powder being required to reach optimal injection depths, reducing waste and allowing for a more efficient process.
Our patented sheath, however, is made of solid calcium metal, not Calcium powder, as the latter has a different melting thermodynamics in its solid state. This allows for the metallurgical additions to be released in the steel melt very carefully, resulting in better metallurgical results. The best way of measuring this is to collect samples (lollipops), and then calculate Ca yield.
AFFIVAL has created a unique feeding system that is installed above the ladle. The machine is able to straighten the cored steel wire while it is being fed into the molten iron, which can be extremely important for good metallurgical results. This allows the injection of the steel to be done at the best speed possible.
In the case Al killed steel the calcium yield is around 25% (an improvement by 32% compared to standard wire cored) and for Si killed steels, results are as high as 38% (+91% improvements). These exceptional results have clearly had an enormous impact on total treatment costs at the iron and metal enterprises.
In order to improve efficiency and the quality of final products, it's essential to optimize treatment processes in the context of a global steel industry. For this reason, a great effort is made to develop innovative technology, such as AFFIVAL conductive steel wires (and the associated equipment) for vertical injection of the metallurgical melting steel. These innovations are able to achieve high metallurgical outcomes with minimal energy and resource consumption, contributing to the economic viability for the steel industry. This is especially true for the calcium treatment which is one of the most costly operations in the entire steel making process.
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