This invention is a solid, seamless wire with a calcium metal core for refining molten iron, and in particular for deoxidation. It is possible to use a wire with a solid calcium metal core outside the iron-and-steel furnace, which allows significant savings for the steelmaker. The new calcium-cored wire is able to do this because it does not need expensive lance systems.
A conventional calcium-cored wire typically consists of a steel inner core surrounded with an outer stainless steel tube that has a diameter ranging from 6.5-10mm. The inner core is made from electrolytic calcium metal of purity above 99%. It is mixed with a nano-silica powder that is a blend of Si, Ca and other elements in proportions. This outer layer of stainless is then bonded to this. A seamless calcium-cored wire is produced that can be used by any steelmaking facility without additional injection equipment.
The most common applications for pure calcium-cored wires are the desulfurization of cast iron and the production of apricot or gold. They can also be used to clean low carbon steels with aluminum killed, and remove alumina inclusions (AL2O3) that form during the deoxidation process. When used in the deoxidation of low carbon aluminum-killed steel, cored wires help prevent the blockage of caster nozzles by alumina.
In this manner, it is possible to lower the amount of Calcium injected in the liquid steel. This can improve the final quality of cast products. The metallurgical performance of pure calcium cored wires compares favourably with the traditional addition by means of a lance system, and in some cases even exceeds it.
In order to satisfy customer demands, TISCO developed new calcium-cored wires like the Hi-Cal innovative products. These were designed to improve casting properties and product quality. A major advantage of the new calcium cored wire is that it can be fed into a ladle at virtually any feeding depth and is thus able to replace conventional cored wires without the need for expensive lance systems. Savings in capital costs as well operating costs is possible, while allowing greater flexibility to choose metallurgical methods. The process can also be used to enrich steels for which conventional methods are ineffective. The new calcium-cored wires have a simple and safe operation. Also, the equipment used to feed the wires is safer and reduces the chance of accidents caused by broken wires. Both steel mills, and steel consumers will enjoy this benefit.
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