Idac - : Annual

IDAC - lJb.
/o3
This report is presented as received by IDRC from project recipient(s). It has not been subjected to peer review or
other review processes.
This work is used with the permission of Central Metallurgical Research and Development Institute.
© 1995, Central Metallurgical Research and Development Institute.
SPONGE/CAST IRON TECHNOLOGY TRANSFER

(EGYPT)
ANNUAL TECHNICAL AND FINANCIAL REPORT
INTERNATIONAL DEVELOPMENT RESEARCH CENTRE (IDRC)

REGIONAL OFFICE, CAIRO
CENTRAL METALLURGICAL RESEARCH & DEVELOPMENT INSTITUTE

(CMRDI)
CAIRO, EGYPT
DEC. 1995
H
ACKNOWLEDGEMENT
This research was carried out under grant from the

International Research Centre (IDRC) - Ottawa, Canada.
The research team of the Gent ral Metallurgical

Research and Development Institute (GMRDI) is gratefri to
this generous assistance and would like to express the
deepest gratitude to their counterparts from IDRC, Ottawa,
Canada and the Regional Office staff in Cairo.
CONTENTS
Page No.
I. INTRODUCTION 1
H. PROJECT STAFF 3
III. ACTIVITIES PROGRAMMED AND EXECUTED 4
IV. OUTSTANDING RESULTS 8
Production of Ductile lron Castings in Selected Foundries

Using Sponge Iron
1. Rubex for MetaL Products 9

2. Industrial Engineering Co. for Casting and Metal Work 17
3. Industrial Progress Company 30
4. Super Gray 39
5. United Company for Iron Castings 46
ANNEXES:
1. Seminar Conducted by CMRDI Research Staff for

the Selected Companis to Introduce Sponge Iron
Technology to Produce Ductile Iron
2. Sand Moulding Studies in Industrial Progress Company
3. Sand Moulding Studies in Rubex for Metal Products

I. INTRODUCTION
In 1988, the former Earth and Engineering Science Division funded a project
entitled "Cast Iron Production from Sponge Iron (88-1058)". This project was
successfully carried out by the Central Metallurgical Research and Development
Institute (CMRDI), in cooperation with the Research and Productivity Council (RPC) of
New Brunswick. The project was focussed on the development of appropriate industrial
practices suitable to small scale foundries in Egypt for the production of ductile iron
made from sponge iron.
The main results obtained during the above mentioned project could be
summarized as follows
(1) High purity pig iron, very low manganese, phosphorous and sulfur is suitable
for the production of ductile iron. It was successfully produced using up to 50%
of sponge iron in combination with steel scrap, Egyptian pig iron or imported
pig iron.
(2) High quality ductile iron castings were produced from charges containing
sponge iron as the main charge constituent. The mechanical properties of the
castings were equivalent to those produced from conventional materials.
Different grades of ductile iron as well as abrasion-resistant, alloyed iron
casting were also successfully produced.
An economical assessment of the processes used showed that the cost of
production of one ton of high purity pig iron using sponge iron was about 570
L.E., compared to 950 L.E. when using imported high purity pig iron.
(4) The resulting new process was successfully introduced in three Egyptian
foundries. Ductile iron rolls of different grades produced in weights up to 2.5
tons showed excellent performances in steel rolling mills.
The present project is concerned with transferring the resulting technology to
small and medium size enterprises in Egypt and in other developing countries
producing sponge iron (India, Peru, Malaysis, Mexico, Indonesia, Venezuela, Argentina
and Brazil). In Egypt it will widen the scope for implementing the technology to a
minimum of 10 small and medium size foundries around the country.
Approved date 23 May 1993.

:
Initiated date: 1 June 1993.
The period covered by this report 2nd Stage of actvities from

: 1 June 1994 to
Dec. 1995.
—2—
II. PROJECT STAFF
Prof. Dr. Adel Nofal project Leader
Dr. Ibrahim Moustafa Researcher
Eng. Mohamed Mourad Ass. Researcher
Eng. Massoud Ibrahim Ass. Researcher
Eng. Ramadan Ibrahim Research Engineer
Eng. Said Emam Research Engineer
Eng. Mohamed Ramadan Technician
Mohamed Mansour Technician
Magdy Moustafa Technician
Fareid Moustafa Technician
AshrafAbd El - Khalik Skilled Labourer
SaIlah Mansour Skilled Labourer
3
III. ACTIVITIES PROGRAMMED AND EXECUTED
A group of 10 foundries was selected and divided into 4 main groups

each group contains 2 or 3 foundries . This selection was based on the
foundry technological level, human resources, marketing and investment
capabilities
For the first two foundries a seminar was held, introducing the
technology and identified the problems that the foundries are presently facing
in producing ductile iron and quality castings with existing material such as
high purity pig iron , steel and cast iron scrap, locally produced pig iron. The
increasing price of low- phosphorous and sulfur pig iron is considered to be
the main problem facing the ductile iron production
From each foundry, 1 to 2 castings with special quality requirements

were selected. The mechanical, physical and chemical properties of the
castings were determined and the actual production cost was calculated.
Together with the foundries personnel, a best practice technology for

each selected casting was determined as follows
- Alloy specifications, chemical composition and metallurgical features,
- Raw materials and charge calculations,
- Melting technique, furnace type, lining, sequence of melting and

alloying, special treatment of liquid iron,
- Moulding and core- making processes
4
Training program for engineers and technicians of participating
foundries to utilize the sponge iron as the main constituent in production of
ductile cast iron was carried out in CMRDI experimental foundry ( pilot scale
produced by the new technology as compared to the conventional one .the
basic principles of utilizing sponge iron in induction and cupola furnaces were
summarized in seminars given to Egyptian Foundries(see Annex 1 )
The different properties of produced castings were evaluated as follows:
- surface quality and internal soundness,

- Specific properties required during services, e.g. tensile
strength and ductility, corrosion abrasion and high temperature
resistance.
- Comprehensive techno- economic evaluation for each of the
castings produced by the new technology was compared to the
conventional one
The Mobile Foundry Laboratory ( MFL)

Using the mobile foundry laboratory ( MEl ), equipped with the
following facilities
- Liquid metal temperature measurements.

- Sampling device for spectrographic analysis.
- Testing of moulding and coresands, e.g. moisture- content,
Compactability, gas - permeability, mould hardness.
- Non- destructive testing of casting soundness, e.g. ultrasonic,
dyepanetrant, eddy- currents ... ect., the operating practices,
and process control procedures have been demonstrated and
monitored in all foundries in which sponge iron technology was
utilized.
Some of specified measurements such as
properties and precise spectro - analysis have been carried out
in laboratories of CMRDI
Apart from useful role of MFI in foundries evaluation, it has
provided an actual support to small and medium size foundries

that cannot afford to have their own control facilities.
- In addition, the sand moulding studies were performed in two
foundries representing the general trends in sand technology in

Egyptian foundries.
(A) Research
(1) Diagnostic Studies and Methodology
For the technology transfer of utilizing sponge iron instead of imported

pig iron ( Sorel ) in the production technology of ductile iron in Egyptian
foundries with technical capabilities to produce ductile iron were selected to

,
adapt and apply this economical technology. The second stage of this project
began at 1 June 1993 to 31 May 1995. The period is covered in this report.
Some castings with special importance in those foundries such as
soundness, surface finishing and mechanical properties were determined to
control the best technological conditions of the applied process.
(2) Justification and Evaluation of Alternative Production System
The economics of the new technology was assessed in cooperation

with the technical personnel of the selected foundries, in companies with the
conventional process of using imported pig iron.
()
(B) Training
(1) A seminar about utilization of.the sponge iron technology in the field
of ductile iron production was conducted by the CMRDI, Foundry and
Casting staff, see Annex 1.
2) A technical training course to use sponge iron with different additions

starting from 10 up to 30%, was conducted in the experimental foundry
of CMRDI (pilot scale). This training course covers both the theoritical
and practical considerations in this technology. The participants were
chosen from every foundry ( 2-5 persons) representing engineers, and
technicians( foundrymen, furnace operators).
7
IV. OUTSTANDING RESULTS
Due to the special nature of this project, and because of the variety of
technical data of the selected castings, it was decided to study the production
technology conditions of five foundries. These selected foundries are
(1) Rubex for Metal Products.
(2) Industrial Engineering Co. for Casting and Metal Work.
(3) Industrial Progress Company.
(4) Super Gray.
(5) United Company for Iron Castings.
Some castings with special importance produced in these foundries were
studied using the following technology sheets
(1) The foundry technical sheet,
(2) Practice technology using sponge iron sheet,
(3) Quality control sheet,
(4) Charge calculation sheets 1,2 for conventional and with using sponge
iron.
—8—
1. RUBEX FOR METAL PRODUCTS
FOUNDRY TECHNICAL SHEET
FOUNDRY NAME: RUBEX for Metal Products
CASTING: (1) Shoulder (Pandrol)

(2)
CHEMICAL COMPOSITION REQUIRED
C% Si% Mn% S% P% Mg% Other Elements
Cast 1 3.7 2.6 0.2 0.01 0.02 0.05
MECHANICAL PROPERTIES REQUIRED:
T.S., kg/mm2 Y.S., kg/mm2 Elongation, % Hardness, BHN
0.2 proof
500 stress (mm) 7 170-24 1
320
PHYSICAL PROPERTIES REQUIRED:
1)
2)
—9—
PRACTICE TECHNOLOGY USING SPONGE IRON
ALLOY SPECIFICATIONS:
1) Chemical Composition:
C% Si°!0 Mn% S0!0 P% Mg% Other Elements
Brand
Cast 3.7 2,6 0.2 0.01 0.02 0.05
Shoulders .
2) Metallurgical Features:
- Spheroidal graphite
- 80% Ferritic matrix
- 20% Pearlitic max.
RAW MATERIAL AND CHARGE CALCULATIONS:
See sheet 2.
MELTING TECHNIQUE:
1) Furnace Type: Induction Furnace
2) Lining: Quartizite
3) Sequence of Melting and Alloying:
- In the bottom of furnace, add, carburizer

- Addition of retume and steel scrap
- Temperature measurement 1430CC.
- Sponge iron addition and deslagging.
- Addition of Fe-Si
4) Treatment of Liquid Iron:
- By using segma method, add FeSiMg

- Inoculation by FeSi.
—10—
MOULDING AND
CORE-MAKING
PROCESSES:
1)
Moulding: Green sand
2) Core:
CASTING DESIGN
(GATING AND
RISERING SYSTEMS):
HEAT TREATMENT:
Fig. (1) Ban droll

metallic pattern.
—11-
QUALITY CONTROL SHEET
EVALUATION OF PRODUCED CASTINGS:
(1) Chemical Composition:

Cast 1 3.49 2.59 0.217 0.016 0.022 0.045
(2) Mechanical Properties:
T.S., kg/mm2 Y.S., kg/mm2 Elongation, % Hardness, BHN

500 320 7 190
(3) Surface Quality:
Bad Satisfactory Good Very Good

'I,
(4) Microstructure:
.,
•# I—.
By Using Imported Pig Iron By Using Sponge Iron
—12—
CHARGING CALCULATION TO PRODUCE DUCTILE IRON WiTHOUT USING
SPONGE IRON (SHEET 1)
Charge Composition Calculation
Raw Materials Other Price Other Price

C Si Mn P S Ele- in ( ) C Si Mn P S Ele- in
Name % % °h % % % ments for I ton % % % % % ments for I ton
Pig iron 60 3.7 2.6 0.2 0.01 0.02 2.22 1.56 0.12 0.006 0.012
Return 20 0.1 0.15 0.4 0.03 0.03 0.02 0.03 0.08 0.006 0.006
Sponge iron 20 4.0 0.1 0.1 0.03 0.03 0.80 0.02 0.02 0.006 0.006
3.04 1.61 0.22 0.018 0.024
Name %
Silicon
Manganese
Other Elements
, 3.04 1.61 0.22 0.018 0.024

Melting Loss
Carbon 10% -0.304
Silicon 10% -0.161
Manganges 10% -0.02
Carburiser 0.964 X 100/99 X 100/90 = 1.08% +0.964
. 3.7 1.431 0.2 0.018 0.024

Calculation of the
Mg = 4.8% +1.100 0.05 .
required quantity of FeSiMg = 2.64 Si = 45%,
alloy lnoculant (FeSi) = 0.3% Si = 75% +0.200
CARBON EQUIVALENT VALUE (CEV) 3.7 2.749 0.2 0.018 0.024 0.05
CHARGING CALCULATION TO PRODUCE DUCTILE IRON USING
Raw Materials .
Other Price Other Price
Name % % % % % % ments for I ton % % % % % ments for I ton
Pig iron 60 3.7 2.6 0.2 0.01 0.02 2.22 1.56 0.12 0.006 0.012
Return 20 0.1 0.15 0.4 0.03 0.03 0.02 0.03 0.08 0.006 0.006
Sponge iron 20 .1.2 - - 0.03 0.03 0.24 - - 0.006 0.006
2.46 1.59 0.20 0.018 0.024
Name %
Silicon
Manganese
Other Elements
2.46 1.59 0.20 0.018 0.024

Melting Loss
Carbon 10% -0.246
Silicon 10% -0.159
Manganges 10% -0.02
Carburiser 1.486 X 100/99 X 100/90 = 1.66% +1.486
'
. 3.7 1.431 0.18 0.018 0.024
Calculation of the
required quantity of FeS1Mg = 2.64% 1.100 0.05
alloy !noculant (FeSi) = 0.3% 0.200
CARBON EQUIVALENT VALUE (CEV) 3.7 2.731 0.18 0.018 0.024 0.05
Fig. 2 : Addition of sponge iron to the induction furnaces.
-15-
I
Fig. 3 : Melting of sponge iron in induction furnace.
r melting of sponge iron.
1 6-
2. THE UNITED COMPANY FOR IRON CASTING
FOUNDRY NAME: The United Company for Iron Castings

(Aly Foad)
CASTING: (1) Pipe fittings

(2) Synatory parts
CHEMICAL COMPOSITION REQUIRED:
Cast 1 3.74 1.31 0.67 0.07 0.05 -

Cast 2 3.7 2.6 0.3 0.02 0.03 0.05
kgImm2 Y.S., kgfmm2 Elongation, % Hardness
25 - - 210
50 45 7 200
1)
2)
—17—
ALLOY SPEC1FICATIONS:
C°!0 Si°!0 Mn0!0 S% P% Mg°!o Other Elements
Casting 1 3.74 1.31 0.67 0.07 0.05 -

Casting 2 3.7 2.6 0.3 0.02 0.03 0.05
Gray Cast Iron Ductile Iron
- Gray cast iron - Nodular graphite

- Flaky graphite - 75% ferritic matrix
- 75% ferritic - 25% pearlitic
- 25% pearlitic
See sheet 2 and 3.
MELTING TECHNIQUE:
1) Furnace Type: Cold blast cupola
2) Lining: Acidic
- Charging of coke
- Charging of metal charge and ferro alloys
- Charging of lime stone
- Mg treatment
- Pouring into a green sand moulds (casting 2)
4) Treabnent of Liquid Iron:
Mg-treatment by using ladle treatment method with FeSiMg

(9% Mg and 50% Si).
Stream inoculation.
-18—
MOULDING AND CORE-MAKING PROCESSES:
1) Moulding: Green sand mould
2) Core: Sodium silicate + sand + carbondioxide
CASTING DESIGN (GATING AND RISERING SYSTEMS):
see Fig. (5)
HEAT TREATMENT:
No heat treatment required for the castings.
—19—

Cast 1 3.612 1.331 0.635 0.042 0.0621 -
Cast 2 3.522 2.553 0.354 0.02 1 0.053 0.05
T.S., kg/mm2 Y.S., kg/mm2 Elongation, % Hardness HV

1.26 - - 270
2.52 45 9 180

v,
(4) Microstructure:
Gray Cast Iron Ductile Cast Iron
—20—
CHARGING CALCULATION IN PRODUCING GRAY CAST IRON (SHEET 1)
Raw Materials . Other Price Other Price

C Si Mn P S Ele- in ( ) C Si Mn P S Ele- in ( )
Pig iron 75 4.2 1.56 0.80 0.07 0.05 3.175 1.175 0.60 0.525 0.038
Return 25 3.7 1.3 0.6 0.07 0.05 0.925 0.325 0.15 0.018 0.013
4.1 1.5 0.75 0.07 0.05
Name %
Ni
Silicon
Manganese
Other Elements
. 3.6 1.375 0.125 0.049 0.037
Melting Loss
Carbon 10% -0.4
Silicon 10% -0.15
Manganges 10% -0.08
Carburiser
'
. 3.7 1.35 0.675 0.07 0.05
Calculation of the
required quantity of
p.g alloy
CARBON EQUIVALENT VALUE (CEV) 3.7 1.31 0.67 0.07 0.05

CHARGING CALCULATION TO PRODUCE GRAY CAST IRON USING SPONGE
IRON (SHEET 2)

Pig iron 50 4.2 1.56 0.8 0.8 0.07 2.1 0.78 0.4 0.04 0.03
Return 25 3.7 1.3 0.6 0.6 0.05 0.925 0.325 0.15 0.017 0.013
Sponge iron 25 1.2 - - - 0.03 0.30 - - 0.007 0.007
3.325 1.105 0.55 0.064 0.05
Name %
NJ Silicon 0.316 FeSi = 0.316 x 100/60 x 100/90 = 0.585% +0.316

N.)
Manganese 0.175 FeMn = 0.175x100/82x100/90 = 0.237% +0.18
Other Elements
3.325 1.421 0.725 0.064 0.05

Melting Loss .
.
10% . -0.333
Carbon
Silicon 10% -0.111
Manganges 10% -0.06
Carburiser Coke = 0.708x1 00/90x1 00/40 = 1.96% +0.708
3.7 1.31 0.67 0.064 0.05

Calculation of the•
alloy
Every charge 300 kg 50%: P.1., 25% Return, 25% Sponge iron.
CHARGING CALCULATiON TO PRODUCE DUCTILE IRON USING SPONGE
IRON CSHEET 3)

% % % % for I ton % % % % % ments for I ton
Name % %
Pig iron 40 4.2 1.56 0.8 0.07 0.05 1.68 0.624 0.32 0.028 0.02
Return 25 3.7 1.3 0.6 0.07 0.05 0.925 0.325 0.15 0.017 0.016
Sponge iron 35 1.2 - - 0.03 0.03 0.42 - - 0.011 0.011
3.025 0.949 0.47 0.056 0.043
Name % .
Silicon 0.458 FeSi = 0.458 x 100/60 x 100/90 = 0.848% +0.458

Manganese +0.18
Other Elements .
3.325 1.421 0.725 0.064 0.05

Melting Loss .
Carbon 10% 0.3

Silicon 10% -0.095
Manganges 10% -0.05
Carburiser Coke = 0.974x100/90x100/40 = 2.7% 0.975
3.7 1.312 0.423 0.055 0.043

Calculation of the
required quantity of FeSiMg = 1.83% 0.913 -0.03
Inoculant = 0.5 0.375 '
alloy
Every charge 300 kg

CASTING DESIGN
78
Riser
Ingate
Sprue
Runner
Foundry united Co. for Iron Castings

Name
Part Name Pipe fittings
Material Ductile Cast Iron
Dimension, Sprue Runner Riser
cm2 e
Area 7.7 11.6 5.8 9.6cm
Fig. 5: Casting design of selected product.
No. 1 1 1 3
I
- •
-
'-
:Zm. - - -.. - - .- -
-—
I
1
r
(a)
Fig. 8 : Pouring of grey cast iron using flaskless method.

—26—
CO
;i.-'
Fig. 11: Pouring of ductile iron.
—28—
\
-
r —
t)
'•
-1'-' " \
k
Fig. 12: Grey cast iron castings.
Fig. 13: Ductile iron castings.

3. INDUSTRIAL PROGRESS COMPANY
FOUNDRY NAME: Industrial Progess Co.

(Mohamed Khamis) - Zagazig
CASTING: (1) Pipes fitting.

(2)
Cast 1 3.6 2.5 0.2 0.02 0.03
MECHANICAL PROPERTIES REQUIRED :
T.S., kg/mm2 Y.S., kg/mm2 Elongation, % Hardness
50 45 7 200
1) Good machineability
2) Enough toughness to resist impact.
3) Corrosion resistance.
—30—
PRACTICE TECHNOLOGY USING SPONGE
C0!0 Si°!0 Mn°!0 S% P% Mg% Other Elements
Cast 1 3.6 2.5 0.25 0.02 0.03 0.05
- Nodular graphite
- 90% ferritic matrix
- 10% pearlitic
See sheet 2.
MELTING TECHNIQUE:
1) Furnace Type: Cold blast cupola
2) Lining: Acidic
- Charging of coke
- Charging of metal charge and ferro alloys
- Tapping
- Mg-treatment and stream inoculation
- Pouring into a green sand moulds.
- Mg-treatment using ladle method with materials (FeSIMg 9% Mg

and 50% Si).
- Stream inoculation.
—31—
2) Core : Sodium silicate sand + carbondioxide
See Fig. (14)
HEAT TREATMENT:
—32—
Cast 1 3.562 2.428 0.227 0.021 0.042 0.05
48 42 10 175
(4) Microstructure:
- Nodular graphite in ferritic matrix.
p.
—33--
IVMI t.ItIML I I
(WITHOUT SPONGE IRO) (SHEET I)
Raw Materials .
. Other Price Other Price
Name % % % % % % ments for 1 ton % % % % % ments for I ton
Pig iron 75 4.2 1.5 0.1 0.07 0.05 3.15 1.125 0.075 0.052 0.03
Return 25 3.6 2.5 0.3 0.03 0.02 0.9 0.625 0.1 0.007 0.005
4.05 1.750 0.175 0.059 0.035
Name %
Silicon
Manganese
Other Elements
2.922 2.78 0.685 0.277 0.061

Melting Loss 0
Carbon 10% 0.4

Silicon 10% -0.2
Manganges 10% -0.01
Carburiser
3.6 1.55 0.16 0.059 0.035

Calculation of the
required quantity of FeSiMg 1.7% 0.85
alloy Inoculant 0.5% 0.375
Every charge: 300 kg

Raw Materials . .
Pig iron 50 4.2 1.5 0.1 0.07 0.05 2.1 0.75 0.05 0.035 0.025
Return 25 3.6 2.5 0.3 0.03 0.02 0.9 0.625 0.075 0.007 0.005
Sponge iron 25 1.2 - - 0.03 0.03 0.4 - - 0.007 0.007
3.4 1.375 0.125 0.049 0.037
Name %
Li.) Silicon
Manganese
Other Elements
3.6 1.375 0.125 0.049 0.037

Melting Loss 0
Carbon -0.34
Silicon -0.1
Manganges -0.01
Carburiser Coke = 0.54 x 100/90 x 100/400 = 1.5 +0.54
3.3 2.6 0.625 0.277 0.061

Calculation of the
required quantity of FeSiMg = 1.7% 0.85
alloy Inoculant = 0.5% 0.35
Every charge 300 kg.

—7'-----
CASTI\G DESIGN
b
e
12
d
Ingate
Runner Extension
Runner
ç Mold parting S prue
0 Foundry Industrial progress Co.

Name I
Part Name Pipe Fitting

D . I
Dimension. Sprue Runner Irigate Riser
cm2 .
Area 2.67 4 2 7.1

Fig. 14 : Casting design of selected casting. 1 1. 2
No. 3
Fig. 15: Tapping of molt en metal from cupola furnace (2.5 tonslhr)
Fig. 16 : Mg treatment of molten metal.
—37—
Fig. 17: Pouring the molten metal (ductile iron) into mould cavities.
-'
Fig. 18 : Machining of casting (the company has two machining workshops one of
them is very old - since 1886,
see the picture. It is still working uptill now, the other is modern one.
—38-
4. SUPER GRAY
FOUNDRY NAME: Supper Gray
CASTING: (1) Plumbing parts

(2)
Cast 1 3.2-3.4 2.5-2.7 0.4-0.7 0.06 0.3 - -
MECHAN ICAL PROPERTIES REQUIRED:
T.S., kglmm2 Y.S., kg/mm2 Elongation, % Hardness
25 180
1) Good strength
2) Good corrosion resistance.
—39—
PRACTICE TECHNOLOGY USING SPONGE IR6N
1) Chemical Composition
C0!. SW. Mn°!. S0!0 P0!0 Mg% Other ELements
Cast 1 3.2 2.5 0.4

0.06 0.3
Cast 2 3.4 2.7 0.7
- Flaky graphite
- Pearlitic matirx
See sheet 2.
MELTING TECHNIQUE:
1) Furnace Type: Cold blast cupola 1 ton/hr
2) Lining: Acidic
- Charging of coke
- Charging of metal charge and ferroalloys
- Tapping
- Pouring
No heat treatment required.
—40--
2) Core: -
See casting design (Fig. 19)
HEAT TREATMENT:
No heat treatment required.
—41—
C% Si% Mn°!0 S% P% Mg% Other Elements
Cast 1 3.234 2.513 0.512 0.08 0.08 0.5 -
27 . - 200
v/
(4) Microsfructure:
- Flaky graphite in a pearlltic matrix accompanied with some
non-metallic inclusions.
—42—
USING CONVENSIONAL RAW MATERIAL (SHEET 1)
Raw Materials
C Si Mn P S Ele- in ( ) C Si Mn P S Ele- in (
Cast iron scrap 20 3.2 2.5 0.8 0.5 0.08 0.64 0.5 0.16 0.1 0.016
Steel scrap 20 0.16 0.15 0.6 0.03 0.03 0.032 0.03 0.12 0.006 0.006
Pig iron 30 4.2 1.8 0.8 0.07 0.05 1.26 0.54 0.24 0.021 0.015
Return 30 3.3 2.6 0.55 0.5 0.08 0.99 0.78 0.165 0.15 0.024
. 2.922 1.85 0.685 0.277 0.061
Name %
Silicon 0.93 FeSi = 0.93 x 100/60 x 100/90 = 1.722% +0.93

Manganese
.
Other Elements
2.922 2.78 0.685 0.277 0.061

Melting Loss
Carbon -0.3
Silicon -0.18
Manganges 0.06
Carburiser Coke = 678 x 100/90 x 100/40 0.678
'
3.3 2.6 0.625 0.277 0.061
Calculation of
.
alloy
9 kg coke/i 00 kg 1 kg FeSi
CHARGE CALCULATION USING SPONGE IRON (SHEET 2)
Raw Materials . . •
Cast iron scrap 20 3.2 2.5 0.5 0.5 0.08 0.64 0.5 0.16 0.1 0.016
Steel scrap 20 2.1 - - 0.03 0.03 0.42 - - 0.006 0.006
Pig iron 30 4.2 4.2 0.8 0.07 0.05 1.26 0.54 0.24 0.021 0.015
Return 30 3.3 3.3 0.55 0.5 0.08 0.99 0.78 0.165 0.15 0.024
3.31 1.82 0.565 0.277 0.061
Name %
Silicon 0.93 FeSI 0.96 X 100/60 X 100/90 = 1.77% +0.96

Manganese
Other Elements
3.31 2.7 0.565 0.277 0.061

Melting Loss
Carbon
Silicon -0.18
Manganges 0.05
Carburiser
.,.
. 3.31 2.6 0.515 0.277 0.061

Calculation of the
p.g alloy

LJLSI(IN
Sprue Vents
IL___
0
Runner
Runner Extension
Ingate
Foundry Supper Gray
Name
Part Name Plumbing parts
Material Gray cast Iron
Dimension, Sprue Runner Ingate Riser
2
cm
Fig. 19 Casting design of selected casting. Area 7.7 11.6 5.8 --
No. 1 1 2 '—
5. INDUSTRIAL ENGINEERING COMPANY
FOR CASTING AND METAL WORKS
FOUNDRY NAME: Industrial Engineering Co. for Castings and Metal Works.
CASTING: (1) High pressure water valves.

(2) Pipes fittings
MATERIAL: Grey cast iron
Cast 1 3.5 1.85 0.32 0.08 0.4 - -

Cast 2 3.5 1.85 0.32 0.08 0.4 - -
T.S., kg/mm2 Y.S., kg/mm2 Elongation, % Hardness
25 - - 280
1) Good machinability
2) Corrosion resisance.
—46—
C°!0 Si% Mn% S°!0 P% Mg% Other Elements
1 3.5 1.85 0.32 0.08 0.4 - -

2 3.5 1.85 0.32 0.08 0.4 - -
- Flaky graphite
- Pearlitic matirx
See sheet 2.
MELTING TECHNIQUE:
1) Furnace Type: 1 ton/hr cupola furnace
2) Lining : Acidic lining
- Charging of coke
- Charging of metal charge (steel scraps, returns)
- Charging of sponge iron
No Mg treatment.
—47—
2) Core: Cemented sand core
See Fig. (20)
HEAT TREATMENT:
no heat treatment required.
—48—
Si% Mn% S% P% Mg% Other Elements
Cast 1 3.392 1.823 1.823 0.283 0.085 0.414 -
26.6 - - 190
vf
(4) Microstructure:
- Flaky graphite in
a pearlitic matrix
—49—
CHARGE CALCULATION TO PRODUCE GRAY CAST IRON WITHOUT USING
Raw Materials Other Price Other Price

C Si Mn P S Ele- in ( ) C Si Mn P 5 Ele- in (
Cast iron scrap 70 3.2 1.7 0.7 0.4 0.09 2.24 1.19 0.49 0.28 0.063
Return 30 3.5 1.6 0.32 0.4 0.08 1.05 0.48 0.098 0.12 0.024
Furnace Additions 3.39 1.67 0.586 0.40 0.087
Name %
Silicon 0.34 FeSi = 0.34 x 10/55 x 100/90 = 0.68% +0.34

LT
C Manganese
Other Elements
339 2.01 0.586 0.40 0.087

Melting Loss
Carbon 10% -0.16
Silicon 10% -0.06
Manganges 10%
Carburiser
3.39 1.85 0.526 0.40 0.087

Calculation of the
required
p.g alloy
CARBON EQUIVALENT VALUE (CEV) 3.39 1.85 0.526 0.40 0M87
Charge wt. - 105 kg cast iron scrap. -45 kg return. -15 kg coke. - 1.020 kg FeSi
CHARGE CALCULATION TO PRODUCE GRAY CAST IRON WiTH USING
Raw Materials
. Other Price Other Price
Cast iron scrap 50 3.2 1.7 0.7 0.4 0.09 1.60 0.85 0.35 0.200 0.045
Sponge iron 30 1.2 - - 0.03 0.03 0.36 - - 0.015 0.015
Return 20 3.5 1.6 0.32 0.4 0.08 0.70 0.32 0.064 0.080 0.016
Furnace Additions 3.39 1.67 0.586 0.40 0.087
Name %
Silicon 0.78 FeSi = 0.78 x 100/55 x 100/90 = 1.57% 0.78

—a
Manganese
Other Elements
2.66 1.95 0.414 0.295 0.076

Melting Loss
Carbon 10% -0.26
Silicon 10% -0.1
Manganges 10% 0.040
Carburiser Coke = 1.1 x 100/90 x 100/40 = 3.1% 1.1
3.5 1.85 0.374 0.295 0.076

Calculation of th.e
alloy .
CARBON EQUIVALENT VALUE (CEV) 3.5 t85 0.374 0.295 0.076
- 75 kg cast iron scrap. - 45 kg sponge iron.. - 30 kg return. - 20 kg coke. - 2.3 kg FeSI

Charge wt.
___________ _______________________________________
I
CASTING DESIGN
—
Riser *
Riser
S
Ingate
Runner
Runner
Ingate
Foundry Industrial Engineering (o. for casting and \letal

N a iii e
Part Name Valve

Material Gray cast Iron
D i in e fl Si 0 fl. Sprue Runner Ingate Riser
2
cm
Fig. 20: Casting design of selected casting. Area 7.7 11.6 5.8 13.5
No. 1 1 — 2 3
1
Fig. 21: Charging process of I ton/hr cupola furnace.
Fig. 22 : Preparation of moulding to get metallo graphic and tensile samples.
—53—
Fig. 23: Taping of molten metal from the cupola furnace.
Fig. 24 : Pouring of molten metal into sand moulds.

Fig. 25 : Shake out of the casting from flaskiess moulding.
Fig. 26 : Fittling of the casting.
—55—
Fig. 27 : Machining after casting.
'—'. .:
:
Fig. 28 Pipes fittling of 16" sanatary gray cast iron
:
(an example of pig size spare part produced by the company)
—56—
Fig. 29 : Assembly of valves produced by the company in an extended production
area in the company.
Fig. 30: 16" diameter water valves produced by the company.
—5?—
ANNIX I
USAGE OF SPONGE IRON
IN CUPOLA FURNACE
THEORETICAL BASIS
SEMINAR HELD FOR FOUNDRIES,

HAVING ONLY CUPOLA FURNACES
I Introduction
The application of DRI in ferrous.-foundry operations began about 1963, arid
since then, it has proved to be a very desirable material for a number of specific
applications. 1-lowover, it is difficult to make many broad generalizations about the etlüct
of on foundry operations because of the many different types of cast iron and steel
that are made and the wide variety of melting processes that are used to produce the
molten metal. In some instances a material that is ideal for one type of melting process
might be entirely unsuitable for another.
About 70 percent of the ferrous castings produced today are made from gray
on. l)uctilc ii on accounts for about 15 percent and malleable iron for about 5 percent.
[lie ieinuiiiieq it) percent are made from steel.
in years, the use of ductile iron has been increasing, arid this is bound
10 hove a significant effect on the type of charge materials that will be required in the
future. For example, the chromium content of ductile iron must be kept to a minimum on
account of its chill-inducing effect, and in some specifications for fernitic ductile iron, the
content must be kept below 0.35 percent. Tramp elements such as
titanium, tin, lead, arid arsenic, which are often in commercial scrap, must
also be because they inhibit the formation of nodular graphite.
[he melting proCesseS generally used ri foundries include electric arc:
1
furnaces, electric induction furnaces, cupola furnaces and reverberatory furnaces (air
furnaces). The cupola furnace is limited to the cast iron grades because it is operated
with a bed of incandescent coke in the hearth. Under this condition, it is impossible to
prevent a high content of carbon from dissolving in the metal. The electric-arc and the
electric-induction furnaces, however, can be used for all the different grades of iron and
steel.
In the manufacture of gray iron castings, the percentage of return material from
the foundry operation included in the charge generally runs from about 8 percent in pipe
casting to about 50 percent in small foundries making castings with heavy risers. The
balance of the charge must come from new iron units. For ductile and malleable iron the
charge will contain about 55 percent return material, and for steel it will be about 60
percent. The new iron units that make up the balance of the charge generally come
from the cheapest source that can be obtained, providing that the chemical composition
of the melt does not include elements that are harmful to the physical properties of the
castings. Generally the cheapest source available is steel scrap; however, it often
contains undesirable tramp elements. In the past when it was necessary to avoid all
types of undesirable contaminants, it was necessary to use pig iron instead of scrap.
Pig iron is the most expensive form of iron units, but it is purchased to strict chemical
specifications and does not contain harmful residual elements. Today DRI can be used
in place of either scrap or pig iron, and like pig iron, DRI can be purchased with a known
chemical composition and can be obtained free from any harmful residuals.
Table ( 1) shows a range of composition typical for one type of DRI pellets
currently available for foundry use. The percentage of carbide or pearlite stabilizers
(e.g. chromium, vanadium, molybdenum, copper, nickel, tin and boron) and the
percentage of nodular-graphite-formation inhibitors (e.g. lead, titanium, aluminium,
antimony, bismuth, arsenic and zirconium) are extremely low. In many foundry
2
,1
operations, it is also very important to have a low titanium and aluminium content to
decrease the chances of the formation of pin-holes in the castings.
Table ( 1): Range of chemical composition of Midrex DRI.
Degree of Metallization 92 or greater

Fe (total) approximately 92%
C* 0.8tol.7%
S102 1.25to2.0%
A1203 0.5tol.2%
CaO 0.31o1.7%
MgO 0.1 to 0.5%
MnO 0.06 to 0.12%
Cr203 0.015 to 0.02%
P 0.007 to 0.04%
S 0.OO2toO.01%
Na20 approximately 0.15%
K20 approximately 0.10%
Ti02 0.01 to 0.46%
V approximately 0.15%
PbO approximately 0.0025%
CuO approximately 0.024%
Sn02 approximately 0.015%
ZnO approximately 0.02%
As203 approximately 0.002%
*higher contents possible.

Degree of Metallization x Fe (total) = Percent Metallic Iron.
In some instances, where the percentage of pig iron used in the charge is fixed
at a relatively low amount because of the carbon content desired in the product, the use
of relatively inexpensive scrap for the balance of the charge is precluded - because of
3
'I
high residuals in the scrap. In such cases the use of DRI pellets with the pig iron might
make it possible to use some inexpensive scrap, and through dilution keep the residuals
in the final melt within an acceptable range.
Low-sulfur DRI is particularly advantageous in electric furnace melting where
considerable time can be saved by not having to remove sulfur in the melting furnace.
In addition to the chemical composition, the physical characteristics of DRI are
also an important consideration in foundry operations because of their influence on
material storage, on handling and charging, and on the operating performance of the
particular type of melting unit involved. DRI is commercially available in the form of
pellets, lumps, mixtures of lumps and pellets, briquettes, and fines. DRI pellets are
spherical and fairly uniform in shape and size, about 6 to 16 mm (1/4 to 5/8 in.) in
diameter. They closely resemble the oxide pellets from which they were produced.
DRI lumps generally has a wider range of particle sizes, ranging from a few
extreme fines up to pieces about 30 mm (1-1/2 in.) in diameter. The fines are caused by
thermal and mechanical degradation of the ore lumps during the reduction process.
Some DRI plants process mixtures of oxide pellets and lump ores and produce a more
heterogeneous material.
Because of the porosity and high specific surface area of DRI pellets and
lumps, they may reoxidize when heated to 200°C (400°F) or remain in contact with
moisture while in storage. Although it is not difficult to keep DRI pellets and lump away
from excessive temperatures, protecting them from moisture requires the use of
covered storage areas.
Another type of DRI is in the form of briquettes. In some plants, DR1 fines and
4
even DRI pellets have been compressed into strong, dense briquettes. The briquetting
is done either hot or cold. In either case, the DRI must be protected from oxidizing
conditions unit after the briquettes are formed. The high density of the briquettes, about
5 to 6 grams per cc (0.18 to 0.22 lb/cu in.), and the low specific surface area increase
the resistance of the briquette to reoxidation. In some briquettes a binder containing
carbon is used, and this makes them very attractive for foundry use.
The major difference between DRI and the conventional foundry charge
materials, such as pig iron and clean scrap, is the relatively high gangue content, about
3 to 6 percent, and the unreduced iron oxide content, about 41012 percent, of the DRI.
The amount of gangue depends almost entirely on the gangue content of the raw
material from which the DRI was made. The amount of unreduced iron oxide, however,
depends on the DRI process, on the type of raw material used, and on the manner in
which the DRI was shipped and stored.
For foundry application it is preferable to have DRI with a very low gangue
content. In the cupola furnace, which is designed for effective separation of liquid metal
and slag, the additional slag volume formed by fluxing the gangue is not particularly
objectionable except that it causes a slight increase in the fuel requirements and a
decrease in melting rate. In the electric arc furnace, a voluminous foamy slag on top of
(he liquid metal is desirable, so long as the slag volume is not excessive, because slag
protects the refractories from the direct radiation of the electric arc. This slag is readily
temoved prior to tapping, but if the amount is excessive, it increases the operating time
and the energy requirements. In foundries using induction furnaces, it has been
reported that the additional slag is objectionable, and that unless the amount of DRI in
the charge is limited to 10 to 15 percent, it is necessary to use an frntermediate
deslagging operation which causes significant delays and increases the energy
requirements.
5
In general, a high degree of metallization is desirable for DRI used in foundries
because additional energy is required to reduce the unreduced iron oxide. When the
charge contains 3.0 to 4.0 percent carbon, the degree of metallization should be at
least 95 percent. However, in steel foundries where the carbon level is 1.0 to 1.5
percent, 90 percent metallization may be sufficient.
Because of its desirable chemical composition, increasing availability and
favorable cost, DRI is taking an increasingly important place in foundry operations. DRI
with a high degree of metallization, a low gangue content and freedom from undesirable
tramp elements is particularly well suited for the production of ductile iron and high-
grade cast iron that must meet stringent quality requirements.
2.2. Melting of Sponge Iron in Cupola Furnaces
A cupola is a vertical, shaft furnace in which the major fuel is metallurgical
foundry coke. A burden of solid material, charged into the top, descends counter
current to a flow of hot gases that transfer heat to the burden until the metal and slag
melt and flow into the hearth.
The cupola is started with a bed of coke onto which scrap, return foundry
material, and at times pig iron are batch charged in layers alternately with layers of coke
and flux. Air blown in through tuyers, near the bottom of the cupola, burns the coke
above the hearth and produces the hot gases. The coke burned near the tuyers is
replaced by the charged coke that descends from the top of the furnace.
In this process the size of the DRI is very important, and large lumps or large
briquettes are definitely preferred. Fines are of practically no value if they are not
briquetted because they would be carried out of the furnace top with the flow of gases.
6
Small DRI pellets can cause operating problems because they trickle down through
voids in the material charged below them and melt in advance of the layer of material
with which they were charged. This causes the upper layers to become depleted in DRI
pellets. To obtain a uniform silicon content in the metal when this occurs, it is necessary
to readjust the ferroalloy addition at the beginning and the end of each new run to
compensate for the melting of the DRI pellets in advance of their respective charges.
With larger size DRI material this readjustment is not necessary.
Another problem with DRI pellets is that they pack more tightly in the charge
layers than conventional charge materials and cause a higher pressure drop and a
slight increase in wind-box pressure. This may limit the melting rate if the wind-box
pressure is already at the upper limit of the blower.
The residual iron oxide content of the DRI is also a matter of great concern
because in cupola operations all of the iron oxide is reduced to metallic iron. Because
the reduction of iron oxide requires additional coke, both as a reductant and a fuel, the
operator must determine how much additional fuel is required, before the material is
charged into the furnace so that the proper burden to coke ratio can be used in the
charge. The higher coke requirement with DRI pellets results in a corresponding
decrease in cupola melting capacity.
The unreduced iron oxide in the DRI causes some loss of silicon and
manganese from the other materials in the charge. Furthermore, DRI contains no silicon
or manganese. Consequently, when DRI is used in the cupola charge for gray iron,
there is a deficiency of silicon and manganese unless additions of these elements are
made to maintain adequate amounts in the metal. Fig. ( 1) shows the.decrease in
melting capacity and the increase the silicon deficiency as a function of the increase in
percentage of DRI briquettes (containing 80 percent metallic iron) used in the charge.
7
111
'S
The additional slag obtained from melting with DR1 in the charge is not a
problem when operating with an acid slag. The cupola furnace is designed to make an
effective separation of liquid metal and slag, both of which are discharged continuously
during tapping. However a slight increase in labor is required to dispose of the larger
quantity of slag.
When the cupola is operated with a basic slag, the amount of slag produced is
higher than with an acid slag.
With DRI in the charge, it becomes even higher because more bases must be
added to flux the acid gangue of the DRI. Unless the gangue content is low, the use of
large percentages of DRI in basic cupola operations will be very limited. Fig. ( 2)
shows the increase in slag volume for an experimental basic cupola run where DRI
briquettes were increased to 60 percent of the charge.
Because of its low content of trace elements, DRI is being used to replace pig
iron wherever practical for diluting the tramp elements that are introduced with scrap
and cause casting problems.
It is obvious that with a short term feed of sponge-iron into cupola furnaces no
definite information could be obtained on the melting process, operating data, and cast-
iron composition and quality. This reverts to the fact that in the continuously-operated
cupola furnace, changes due to a new feed mixture are reflected only after a period of
transition. Additionally, it is known that shaft furnaces react in a relatively sluggish
manner to any changes. Thus, for a short time use of sponge-iron, the real conditions
and effects cannot be recorded with sufficient accuracy. Therefore, during the trials
discussed herein, the cupola furnaces were generally run for on full day with an
identical mixture to the normal operating pattern.
a
Sponge-iron was charged like the other feed materials during the test runs. In
most cases, the sponge-iron had been made of oxide pellets which, due to their
spherical shape and diameters of 10-16 mm, had very good flow properties.
As a result, a proportion of the sponge-iron pellets were trickling down through
holes in earlier charges, thus running ahead of the charge to which they were originally
added. The degree of this downward migration is determined by the relationship
between sponge-iron dimension and shape and the number and size of holes between
the mixture components. It should be reduced if sponge-iron from lump ore is used.
Such material is being produced in increasing amounts. In order to avoid changes of
composition and temperature, a certain migration of sponge-iron should always be
taken into consideration when calculating the charge.
The earliest reports on the use of prereduced materials in cupolas dealt with R-
N briquettes charged into a basic hot blast cupola at Witten, W. R-N
briquettes contained 94 to 96% total iron, approximately 94% of which was in the
metallic state. During the test, the furnace burden was changed from Witten's standard
charge of 70% steel scrap and 30% Krupp Renn Luppen to steel scrap and R-N
briquettes: The percentage of briquettes was increased in steps to observe the
influence of the change in burden on cupola performance. Particular attention was
given to metal chemistry and temperature and to the change in blast pressure. It was
reported that no specific difficulties were encountered during melting of more than 900
tons of R-N briquettes, that control of the highly basic slag was possible at all times,
that the blast pressure increased only slightly and that only a small additional amount of
coke was necessary to compensate for the gangue content in the briquettes.
The first results establishing the feasibility of using metallized pellets for the
production of grey and ductile iron in the cupola were possible in Heats
9
conducted in 60-in experimental cupola, in which steel scrap had been replaced by
increasing amounts of prereduced pellets demonstrated that changes containing up to
70% sponge iron could be melted in an acid cupola. Two full-scale heats in a 108 in
production cupola confirmed those results. The main results obtained may be
summarized in the followings:
- no excessive windbox pressures were created and general cupola
operation was not adversely affected.
- additional coke was required to slag-off siliceous gangue in the pellets (30-
35%) increase in coke consumption when 50-60% sponge iron was used
in the charge.
- as the composition of the gangue made it self-fluxing, no additional
limestone was necessary.
- although the slag volume increased by 140%, this presented no problem
in cupola operation but increased labor to dispose of larger volume of
slag.
- the slag produced was acidic and it would have been impractical to use
this sponge iron in a basic cupola.
-. due to the dilution effect, the percentage of all tramp elements, except Ti,
decreased when steel scrap in the cupola charge was replaced by the
high purity prereduced pellets with approximately 94% total iron; 98% of
which was in the metallic state.
Later T. Makiguchi et melted charges consisting of 80% partially reduced
iron with 78.05% total iron, 29.65% metallic iron, 52.84% FeO, 10.46% Fe203 and 3.9%
carbon together with 20% pig iron in :
i) a hot blast cupola without refractory lining with coke ratio of 40% and
10
combustion ratio of 0.29. The iron yield was 97% but the S-content was
0.159%, too high to be used for actual castings.
ii) a cupola of CO-enriched atmosphere with basic lining. Melting was made
at a coke ratio of 49% and a combustion ratio of 0.13. The iron yield was
98% and the S-content could be reduced to 0.088%.
The analysis of irons melted in both cupolas is shown in the following table
C Si Mn P S
Conventional 3.46 0.20 0.09 0.022 0.159
CO-enrichment 4.25 0.51 0.20 0.052 0.088
The conventional hot blast seems to be advantageous to the CO-enriched one
in the following
a) it has high efficiency of combustion with lower coke ratio.
b) it can be operated without refractory lining.
c) the liningless cupola can be continuously run for a long time without
repairing.
d) slag control is made with ease due to little erosion of refractory lining.
Therefore the authors concluded that the conventional hot blast cupola will be
preferable to the CO-enriched cupola if the desuiphurisation could be easily made
either by trough or ladle treatment.
Metallized pellets containing 92.8% iron were melted with automobile scrap in a
small hot blast cupola, having an inside diameter of 1 It was found that pellets
with a low gangue content and high metallization can be used successfully with
11
automobile scrap in 50-50 ratio: with 100% pellet charge no difficulty was experienced
either. Because of a higher pressure drop with the smaller pellets, a slight increase in
windbox pressure and a 9% increase in coke rate were necessary, and both resulted in
no significant change in production.
At the Rheinstahi Foundry, Muelheim/Ruhr, W. Germany, sponge iron bri-
quettes were charged into a cupola with a 39-in (1000-mm) hearth For
months, 20% of the cupola charge consisted of briquettes (density 5.3 g/m3) containing
1.78% carbon and 92% total iron, approximately 95.5% of which was in the metallic
state. During special the amount of briquettes was increased in steps to
60%.
Figure ( 3) shows the approximate compositions of the charges. The
increased demand for coke to compensate for the roughly 10% oxides in the briquettes
was realized by a corresponding reduction in the metallic charge: this way, the charge
volume was kept constant. As a result, the melting capacity of the furnace decreased
(Fig. 2.1) and the slag volume increased (Fig. 2). The latter did not cause problems
but additional energy is necessary to dispose of the slag.
Up to the 40% level of sponge iron briquettes in the charge, the simplex
operation was used to produce directly regular cast iron (GG-20 quality). No change in
metallurgical structure or strength could be determined during increasing additions of
briquettes. Because of the low Mn content of the sponge iron briquettes, the liquid iron
from charges with higher percentages (50 and 60%) of briquettes was used as a base
for the production of ductile cast iron using the duplex method. It was found that the
sponge iron briquettes are particularly well suited for this application.
In general, it was concluded that sponge iron briquettes are extremely well
12
suited a charge material for cupolas. As in the case of steel scrap, the reliability of the
composition of liquid cast iron obtained during the simplex melting procedure is lower
than with pig iron as the furnace charge. High carbon contents of the sponge iron and
the always uniform and low content of tramp elements are advantageous. If the duplex
technique is being used, the final results become very reliable.
Another deals with the use of sponge iron as a charge material for
cupolas producing malleable and ductile cast iron. Three acid-lined hot blast cupolas
were used, one with a 90-in. (2300-mm) and two with 110-in. (2800-mm) hearth
diameter, having, respectively, 59-in. (1500-mm), 87-in. (2200-mm), and 47-in. (1200-
mm) melting zone diameters. The sponge iron consisted of pellets, lump ore, and
briquettes with 0.7-1.6% carbon and 90 to 95% total iron, 92-96% of which was in the
metallic state.
Figure ( 4) shows the additional coke consumption in relation to the amount of
sponge iron in the charge. Curve 1 was obtained with a constant wind temperature of
approximately 840°F (450°C) during the production of white, malleable cast iron (GTW).
Curve 2 represents results from another furnace during the production of black,
malleable• (GTS) and nodular (GGG) cast iron. In this furnace, the wind temperature
was changed in steps from normally 300°F (150°C) with 0% sponge iron to 840°F
(450°C) with 20% and more sponge iron. The difference between curves 1 and 2
represents the energy introduced with the hot wind. If an adjustment of the wind
temperature would not have been possible, curve 2 would be identical with curve 1. The
lower part of Fig. ( 4) indicates the corresponding decrease in melting capacity for
case 1 (GTW).
When sponge iron pellets were used, the iron temperature and composition
varied and a large amount of viscous slag was produced during the startup period. The
13
reason for this behaviour is that the smaller pellets drop through the open space of
lower charges and melt several charges in advance of the charge to which they were
originally added. The upper charges become increasingly depleted in pellets. This result
In agreement with earlier findings by Hafner and To obtain a uniform Si level,
it is necessary to adjust ferroalloy additions at the beginning and end of the heat to
compensate for the melting of pellets in advance of their respective charges. K.
Hornung et determined that with sponge iron briquettes the this problem does not
exist.
No additional wear of the furnace lining was determined during the production
of black, malleable and nodular cast iron with prereduced material. Lining wear was on
the high side even with only small amounts of sponge iron in the cupola charge if white,
malleable cast iron was made (Fig. 5). The amount of slag increased in all cases as
expected.
Figure ( 6) shows the changes in C and Si content of the cast iron at different
proportions of metallized pellets in the charge. In all cases, the C-content, which was on
the high side if no sponge iron was used, could be lowered with attention advantages in
melting and positive results in respect to strength and hardness due to a changed C to
Si relationship. The variation of the composition, represented by the standard deviation
(S in Fig. 9), increased with pellets but was not changed if briquettes were used.
In the USA, among others, Newbury and Talladega foundries, both in
Talladega, Ala., used sponge iron in their basic cupola In all cases, pellet
additions to the charge were limited to 5, 10, or 15%. It has been reported that at those
levels excellent results were obtained. In agreement with the trials described in more
detail above, the coke requirement increased slightly, the basicity of the slag decreased
(which could be offset by the addition of limestone), the dilution effect lowered the
14
content of tramp elements (especially P and Mn), and ferrosilicon was added most of
the time ahead of the charge containing pellets to compensate for pellets dropping
through lower layers. The increased slag volume could be separated and handled
without difficulty.
M.G. Geck and W. investigated the effect of replacement of
steel scrap by sponge iron in cupolas with different operating parameters and
production programs shown in Table ( 2).
Table 2): Data relating to cupola furnaces charged with Midrex sponge -iron.
Cupola Furnace Cupola Furnace Cupola Furnace

(1) (2) (3)
Hearth diameter (mm) 2,100 1,950 1,100

Nozzle distance (mm) 1,400 1,250 300
Maximum wind quantity
(cu.m. permin.) 190 150 100
Wind pressure
(mmH2O) 800to 1,000 700to 800 650to 700
Maximum blast tempera-
ture (°C) 600 500 Cold blast
02-addition (%) - - up to 4
Batch weight (kg) 1,200 1,200 600
Coke rate (kg per ton) 190 125 130
Output (tons per hr.) 12.5 12 8 to 9
Basicity of the slag 1.9 1.0 0.5
% CaO + % MgO/% Si02
Production programme Ingot-mould s.-g. iron Grey
special iron, (Duplex process) cast-iron
s.-g., iron.
15
The impact of increasing sponge iron addition has been studied on the
following parameters
- melting characteristics.
- cast iron composition.
- slag quantity
- sulfur content
- metallic yield.
(a) Melting Characteristics
Figure ( 7) shows the coke ratio, melting performance and the temperature of
the cast iron as a reference of sponge iron proportion. As shown, the coke ratio
increases by approximately 6 kg per ton for a 10% increase of sponge-iron in the
charge. Compared with published this increase in coke consumption is
low. However, the melting and charging conditions have to be considered. Correspond-
ing to the relatively low increase in coke consumption, the melting performance change
is insignificant. Due to the small size of the pellets and their large specific surface,
which is about 20 times larger than that of pig-iron, pellets heat up with a considerably
higher speed in the upper part of the shaft. Consequently, heat utilization is more
favourable. Therefore a slightly improved performance with a reduced coke rate is quite
possible. As shown, the temperature of the cast-iron in the launder remainded almost
unchanged under the circumstances described above.
(b) Chemical Composition
Figure ( 8) depicts the variation of some essential elements in the cast-iron
and the slag as a function of the sponge-iron added. Fig. ( 8a) shows that up to an
16
addition of 10% of sponge-iron, the carbon content remained unchanged and dropped
slightly at 25 percent. The values representing the iron content of the slag do not
depend upon the sponge-iron content; they are scattered in the range of 0.2%. This
means that at the operating conditions of this furnace, the residual iron oxides added
with the sponge-iron have been reduced almost completely. As in the case of carbon, a
significant reduction of the silicon content only occurs at a sponge-iron addition of 25%
(Fig. 8b). Fig. ( 8) also shows the sulfur contents of the cast-iron. Also indicated are
the basicities B which, in agreement with the literature, were calculated as B = %CaO +
MgO/Si02. Here it is also evident that, with up to 20% of sponge-iron in the charge, no
substantial change occurs. Even the higher sulfur content at 25% addition of sponge-
iron seems to revert to a reduction in basicity rather than to the effect of the sponge iron
itself.
(c) Slag Quantity
Figure ( 9) shows the change in the specific slag quantity as sponge-iron in
the charge is increased. The gangue content of the sponge-iron was approximately
3.6%, mainly Si02 and A1203. In furnaces with a basic lining, Si02 content must be com-
pensated to obtain the required slag basicity. In this case, the silicon content of the
coke must be determined at the increased coke rate. In the three cupola furnaces, the
different basicities of the slag lead to very different quantities of basic slag. They were
in the range of 25 kg. per ton for cupola furnace 3 (B = 0.45-0.6), 45 kg. per ton for
cupola furnace 2 (B = 0.95-1.20), and 90 kg per ton for cupola furnace 1 (B 1.65-2.05),
respectively. As expected, the increase of slag quantity is lower in acid than in basic
furnaces. As shown in Fig. ( 10), the method of operation and the slag basIcity in the
cupola bears very heavily upon silicon slagging. Generally, silicon slaggirig increases
with growing amounts of sponge iron whereby silicon together with carbon shares in the
reduction of the residual iron oxides. lt is also understandable that silicon slagging
increases with higher slag basicities.
17
Figures ( 11) and ( 12) compare the test results of all three cupola furnaces.
These figures show that, apart from the influence of the sponge-iron addition,
characteristic differences in the operating methods of the furnaces under investigation
do exist. Such differences are also apparent in the carbon and sulfur contents of the
cast-iron and, to a smaller extent, in the iron-oxide content of the slag (see Fig. 11).
The levels of these elements are determined by the operating method and differ slightly
with increasing sponge-iron in the charge.
The highest decrease in carbon content was found in the acid cold-blast cupola
furnace in which the carbon level is low anyway. Despite constant temperature of the
launder iron (1 ,485-1 .520°C), carburization was less favourable in this furnace.
(d) Sulfur Content
The average sulfur contents are determined by the slag basicity (Fig. 1 ib). In
hot-blast cupola furnaces with basicities of approximately 1.0 and 1.9, higher sulfur
contents may be expected with an increasing sponge-iron addition.
The oxide content in the slag, which is generally low, confirms the high degree
of reduction of residual oxides. For this reason, the iron yield of the three furnaces was
in excess of 99.9%. Since carbon and sulfur content of cast-iron are most heavily
influenced by the furnace operation, they were studied in detail.
Figure ( 12a) shows, as a function of the sponge-iron added, the approach of
the actual carbon content to the equilibrium value, calculated according to the following
relation
% C equilibrium = 1.3 + 2.57 . T (°C) - 0.305 . % Si + 0.03 % Mn
- 0.36 . % S - 0.337 . % P
18
Figure ( 12a) shows that despite constant iron temperatures, the conditions of
carburization deteriorate from furnace 1 to furnace 2 and down to furnace 3.
Introducing the value as a measure for the approach, with = analytical
%C equilibrium and plotting this value in Fig. (. 12b), as a function of the basicity B, it
means that the approach to the equilibrium and, consequently, the carbon content grow
with increasing basicity. It appears to be more likely that kinetic factors cause this
phenomenon, since nothing is known so far about any effect of the slag composition on
the carbon saturation with surplus solid carbon carriers being present. In the case
represented by Fig. ( 12b), the values are somewhat smaller with sponge-iron addition
than without.
Sulfur content plays a decisive role in the production of ductile iron, since in the
cupola, sulfur containing coke is used as fuel, carburizing, and reducing agent and
brings in more than 80% of the sulfur, the low sulfur content of the sponge-iron has no
effect. Therefore, in order to reach a low sulfur content, desulphurization inside or
outside of the furnace is necessary. If desuiphurization is to be carried out in the cupola
furnace, a high slag basicity must be provided for.
In Fig. (' 13) the sulfur content of the iron (Fig. 13a) and the sulfur
distribution ratio (Fig. 13b) are plotted as a function of the basicity B. The influence of
sponge-iron addition appears to be insignificant. The values are in the range of the
lower scatter.
Since slag separation in cupola furnaces can be accomplished without
difficulty, the increased slag quantity causes no trouble when using sponge-iron. The
melting rate is only influenced to an insignificant degree when using this material. The
additional consumption of coke, limestone, and alloying elements does not only depend
19
on the percentage of sponge-iron input, but also on the operational method of the
furnace. Fig. ( 14) represents calculated values which clearly show that both the slag
basicity and the combustion ratio determined the increased expenditure. Furthermore,
consumption figures are influenced by whether pig-iron or scrap are to be replaced by
sponge-iron. In the calculation, neither the utilization of the chemically bound heat by
recombustion of the top gas nor the better heat transfer into the smaller sponge-iron
pieces have been taken into consideration.
(e) Metallic Yield
Since, in cupola furnaces, nearly 100% of the residual iron oxides are being
reduced, this factor does not affect the metallic yield. However, it must be considered
that with both increasing iron-oxide content and increasing gangue content, the cake
and limestone consumptions will grow according to the calculated relationships shown
in Fig. ( 15). The combustion ratio of the too gas, in regard to coke consumption, and
the slag basicity, in regard to gangue content, represent important parameters.
Nevertheless, sponge-iron with a high degree of metallization as generated by the
Midrex process is a desirable feed material for the cupola furnace.
The input cost advantages resulting from the cost relation between pig-iron and
sponge-iron are in favour of sponge-iron, and are almost completely exploited, since the
excess consumption of coke and limestone is very low. For the tests with 25% sponge-
iron input, the cost reduction for the charge material was calculated to be approximat&y
8%.
Sponge-iron has been recently utilized as foundry charge material in
Indian Foundry industry. To date, the total number of foundries in India is over
5000 which are scattered all over the country. Even these foundries are not
sufficient to meet the requirements for some sophisticated and intricate
20
castings, which have to be eventually imported. Furthermore the capacity
itilization of the existing foundries is poor because of a variety of reasons the
chief among them being shortage of power and raw materials. Whenever the
production is not throttled by power shortage, it is either shortage of raw
materials quantity as well as qualitywise (e.g. pig iron, scrap, coke, etc.) and/or
their high prices, which have been responsible for the poor performance of the
foundries. This situation is rather similar to that of the foundry industry in
Egypt.
The first sponge melting trials in a cupola in Indian gave rise to the
following conclusions
I) Up to 25% sponge iron can be easily used in a cupola charge (to replace
pig iron) without causing any significant operational difficulties with higher
percentages of sponge iron in the charge, however, the permeability of the
charge decreases and as a result, the gas flow experiences greater
resistance. This causes increased air pressure in the wind box and
decreased air flow, with 25% sponge, the air pressure increased by about
30% in this case.. Care has to be taken to study this aspect before using
significant percentages of sponge iron in cupolas.
ii) Sponge iron should not be included in the first 6 to 8 charges - if added in
the earlier charges, it causes difficulty in tapping out the liquid iron. This
also ensures that when sponge iron reaches melting area, its temperature
is sufficiently high.
iii) The slag volume of the cupola furnace increases with increasing amounts
of sponge iron in the charge - so more care should be taken in slagging.
With 25% sponge iron, the slag volume increased by about 15-20% in this
trial.
21
iv) The liquid iron temperature is not affected by iron addition.
v) The smelting capacity of the furnace is expected to go down with sponge
iron in the charge - this depends on its gangue content and degree of
metallisation. It is therefore necessary to choose sponge iron with a low
gangue content and as high a degree of metallisation as possible for use
in cupolas.
vi) Like carbon silicon content of the cast iron also goes down, but in this
case the rate of decrease is more rapid.
vii) Titanium content of cast iron melts containing sponge iron is definitely
lower as compared to the normal melts.
The authors expected that in India also sponge iron will be used in greater
amounts in cupola furnaces - as large quantities of sponge iron would be available in
the Indian market. Economic considerations would of course play a role but present
indications are that sponge iron usage would also be economically viable. This would
definitely reduce the titanium content of cupola cast iron in India which should help in
making the production of SG iron in India more popular.
22
(1) R.W. Shields, K.W. Roessing an(1 IL. Bishop, Thermochemical Model of a Basic
I
I-lot-Blast Cupola, Proc. Symp. Process Simulation and Control in Iron and Steel
Making", AIME, p. 167-195 (1966).
(2) S. Tunder, Vetwendung von Fischschwamm bei der in

baischen Heisswiridkupolofen, (Use of Sponge Iron for Pig Iron Production in tho
Basic Hot Blast Cupola), Proc. Congr. ml. sur Ia production el l'utilisalion dos;
minerals reduits, Evian (Mai 1967).
(3) RH. Hafner arid S.C. Glow, Melflnq Iron-ore Pellets in the Cupolu
Proc. Amer. Fouridrymen Society, p. 53-59 (1968).
(4) 1. Makiguchi. T. Tanaka, T. Baha and Ch. Fukuda, 'Utilization of Partial ly

Reduced Iron Ore br Cupola Molting", Proc. 35th International 1-oundry
Kyoto, p. 28-1 to 26-6 (Oct. 1966).
(5) 1. Makiguchi and T. Tanaka, "Utilization of Partially Reduced Iron Ore for Cupola
Melting", Trans. Nat. Res. Inst. Metals, Vol. 11, No. 1, p. 11/19 (1969).
(6) NB. Melcher, W.M. Mahan, "Production of Foundry Iron with Scrap Pro
reduced Pellets", Proc. ICSTIS Suppl. Trans. ISIJ, Vol. 11, Sec. 1 (111) (1971).
(7y H. Motz, Fisenschwammbriketts als Einsatzstoff im Kupolofen und Eigenschaften

des dabei erzeugten Gusseisens, (Sponge Iron Briquets as Charge Material for
the Cupola and Characteristics of the Cast Iron Produced Herewith) Giesserel,
Vol. 62, No. 23, p. 593-599 (1975).
(8) K. Hornung, R. Linkett, H. Schmidth and L. Wilhelm, Eisenschwamrn als

EinsatzstofI fuer Temperguss und Gusseisen mit Kugelgraphit im Kupolofen,
(Sponge Iron as Charge Material for Cupolas for the Production of Malleable and
Nodular Cast Iron), Gieswerei, Vol. 62, No. 23, p. 599-603 (1975).
(9) Anonymous, Use of MIDREX Sponge Iron in the Basic Cupolas of

Talladega Foundries, Tallaclega, Alabama, unpublished reports, Georgetown
Ferreduction Corp., Georgetown, S.C. (1975).
23
(10) MG. Geck and \A/ 'Usc of MIDREX Sponge Iron in Induction and
Cupola Furnaces", Foundry .1 rade pp. 969-989, (Nov. 25, 1976).
(11) MG. Geck and VV. Maschlanka, "Melting of MIDREX Iron in the lnductton and
Cupola Furnacus of Foundries", Indian Foundry Journal, 28 (13), pp. 1
(Oct. 1982).
(12) R. Singh, S. A. Chatteijee, "Melting of Sponge Iron in a Cupola Studies at

11SCO: loot and Alloy Steels", 16, (/), Pp. 235241 (July 1982).
24
E
C
C
'1,
U
•1
0
C
U C
C, 0
C U
0 TO 20 30 40 50 60
% Sponge iron
Fig. ( 1): Melting capacity and silicon loss in relation to the amount
of sponge iron brique ties added to the charge.
14
12
10
C,
C
8
0
C
0 6
E
0
0 10 20 30 40 50 60
Sponge iron briquettes

Fig. ( 2): Amount of slag in relation to the amount of sponge iron
briquetteS to the charge.
25
cc
.1
0.
E
00 u
B
§ oF- 01—
6
4)
E
:o
-J
15 10.5
4)
0
U 14
9.5
.13
N
0) 12 8.5
C
% Sponge iron
4-
C
0
F mOot mould
C Scrap
di Cast Iron;.-
>
4-.
C
di
10 20 30 40 Furnace copocity
0
% Sponge iron briquettes
capacity in relation to
of the test charges. Fig. 4): Coke consumPtion and furnace to the charge.
Fig. 3): ApproXimate compositions the amount of sponge iron added
Fig. ( 5): Lining wear of furnace
401 during the product/on
of white, malleable cast
iron.
50 100 150 200 250
Throughput (T)/16h
3.5
3.0
Fig. ( 6): Carbon and silicon contents 2.5

In relation to the amount of
sponge Iron added to the
charge. The results are re-
presented by the arithmetic
mean x and the standard V 2.0
C
deviation = S. 0
U
1.5
1.0
0.5
0 5 10 15 20 25 30 35
Sponge kon
27
220
H
41 04 £
LI
200
— E
C
02
U
80 U
IL
U
:: 0
13
11
g
u
N 12
0
09
1550
LI
U
1500
4- I
a 0
I-U
E 0
V
F-
25 30 0
0 5 10 15 20 0 5 25
Sponge iron proportIon In %

Sponge Iron proportion in %
remaining burden:
remaining burden ' oppr 5% circulating, 70 to 95% steel scrap
• oppr. 5% circuloting 70 to 95% steel scrap
o oppr. 10% cast iron scro 65 to 90% steel scrap
10% circulating, 65 to 90% steel scrap
coke consumption, Fig. ( 8): Effect of sponge iron on the composition of cast iron
Fig. ( 7): Effect of sponge iron proportion on (cupola No. 1).
Melting capacity, and iron temperature and slag (cupola No. 1).
120
CaO.MgO
Cupola Ii I 1.65-2.05
100
g
—S
*1
80
.->-
60 CaO.MgO
Cupola (/ 2 0.95-1.20
Si02
•1
U 40 CoO +MgO
Cupola 11 3 0.45-0.60
Si02
I 20
0
0 5 10 15 20 25 30
Sponge Iron proportion In %
Fig.( 9): Effect of sponge iron in the cupola

charge on the quality of slag.
12 I
I I I
CaO+MgO
* Cupola C 1
= 1.65-2.05
——
Si01
10 *— — —
— —. — —
*
— — — K
8 - — — CoO +MgO
. Cupola (/ 3
SiO
= 0.45-0.60
U
6 S
0 I Cupola 1/ 2
CoO. MgO
0.95-1.20
4
C
C,
C,
a
0
2
0
0 5 10 15 20 25 30
Sponge Iron proportion in %
Fig. ( 10) : Effect of sponge iron in the cupola

charge on the slagging of silicon.
29
B T(°C)
42 185 1505
C
4'
Br 1.65-2.05
38
"H 105 1510 H
a
34
E
060 1505
B :0.96-1.20
-a
30
B 0.45-0.60
a-
4'
060 1505 U
. 0 10 20
sponge Iron proportion in %
a
"H 0 90
L) cii —. . p
C 105 a b)
— a
- — , 0
185 1505 0 -
a- fr_ ,- 1• C V
0. a C,
C
0
a 80 -___ a.
I 5)
U 0)
C
• 0 0
,* a. 0
2 /
-S 1/- -c
- 3:
L'S 3: K
0
S 70 y*_
U 0 0.4 0.8 1.2 1.6 20 2.4
10 15 20 25 soig baslcity B
5
C
- analytic.
- Sponge Iron proportion Irs Temperature 1480 to 1525 °C
rIG..
C
2, x 1! 1, 8 = Slag basicity equiltbrium
Cupola II 3, o Cupola II Cupola
Fig. ( 12): Approximation to carbon equilibrium as a function

Fig. ( II): Effect of sponge iron on the carbon and sulphur content of of a proportion of sponge iron, b, slag basicity.
casi iron and on the iron content of the slag.
0.25
25
0.20 8=2 ]n =0.25

B 0.5
0.15
8=2 in =0.5
B
C
0. 0
U
Id B = 2 r18 0.25
u.S 10
-c 0.05
C-
B 2 r18 0.5
0
. With sponge Iron < 25%, x Without sponge Iron
IOU Replacing
50 025 Pig It-on

15 0.5
0.25
0.5
C, 20
g
10
I-
Sn 5
-C
-c
p
C- 2
V) 0 50 100 150 200 250 300

-C Sponge Iron input in kgc/ton oF cast iron
0 02 04 06 08 1.0 1.2 1.4 L6 1.8 2.0 CoO.M00 Co,
Slog bosicity B ;
Saig bosicity B Si01 CO
Fig. ( 13): Effect of slag basicity on the sulphur content of the cast Fig. ( 14): Effect of sponge iron on the additional
iron, and on the distribution of the sulphur. consumption of coke and limestone at
different levels of slag basicity (B) and
cornpustion condition in the cupola.
I?
1500°C
S : 2 0.25
B 2 ri 0.5
0.5
8:0.5
Proportion of oxidized Iron in Proporticxi of gangue in
Fig. ( 15): Effect of the proportion of iron oxide and gangue content
on additional coke consumption.
32
ANNEX U
SAND MOULDING STUDIES
IN
RUBEX COMPANY
FIRST REPORT ON OF
THE SAND MIXTURES USED IN DISA
MOULDING LINE IN RUBEX COMPANY
RUBEX foundry used DISA machine for moulding which has the following
advantages:
- Cooling of the return sand before entering the mixture.

- Eliminating of dust and dead clays.
- Separation of shell sands (core sands).
Sand Specifications
The properties of the new as well as the used sand are measured at CMRDI
laboratories and are listed in the following table compared to the sand standard
properties recommended by DISA:
Test Result Standard Value for DISA
(a) NewSand:
64-70 80-100
AFS No. 0.33 mm 0.16-0.2 mm
Average grain size 1.2% 1.5-3.0%
Clay content
(b) Used Sand:
Total clay content 17% 11-13%

Active clay content 9% 7-8%
Dead clay 7% 34%
Loss in igination 5.2% 3.5-4.5%
G.C.S. 1.16 kg/cm 1.7-2.1 kg/cm
Permeability 50 > 50.
Compactability 36% 35-45%
Moisture . 2.8% .. 2-4%
1
1. Grain Size Distribution
The clay free sand samples were screened using a set of sieves belong to
serious "RiO" according to the standard methods.
The mean particle size for moulding sands are of medium size, this suitable for
cores rather than for moulds.
AFS for the used sand is small compared to that standard values suitable for
DISA.
2. Clay Content
Using standard method, the total clay content could be determined and by using
metheline blue test, the active clay part was measured and accordingly the dead clay
was calculated.
(a) Active clay : An accurate percentage (7%) helps to get suitable green
compression strength with good gas permeability, and good compatability, by
increasing bentonite and water addition in the mixture, the moulding parameter
could be deteriorated.
(b) Dead clay content: is very high especially in the backing sand, where this high
content causes a decrease of gas permeability and also decrease of the green
compression strength.
3. Gas Permeability
Due to an increase of the total clay content there is a decrease in gas

permeability of the mixture.
4. Green Compression Strength
Compared with the standard value suited for DISA machine, the G.C.S. is small,
this due to high clay content in the sand mixture.
2
Generally
The apparent deviation of sand properties from the standard values needed for
the proper operation of DISA machine may be attributed to:
- The properties of sand are not regularly monitored.

- The sand drum unit is not in operation.
3
SECOND REPORT ON
SPECIFICATIONS OF THE SAND MIXTURES
USED IN DISA MOULDING LINE IN
RUBEX COMPANY
Test Results Standard Values for DISA
1. Total clay content 15.0% 11-13%

2. Active clay content 9.3% 7-8%
3. Dead clay 5.7% 3-4%
4. Loss on ignition 4.0% 3.5-4.5%
5. G.C.S. 1.4 kg/cm2 1.7-2.1 kg/cm2
6. Permeability 65 > 50
7. Compactability 38 35-45
8. Moisture content 2.8% 2-4
9. Wet tensile strength 12 g/cm2 > 20 g/cm2
Analyses proved that most measuements are within the accepted ranges for
DISA requirements. The relatively higher values of total and active clay contents are in
contradiction with the considerably low wet tensile strength. This may be attributed to
the prese'nce of relatively high contents of free ions (salts) in the used water. These
ions are accumulated in the sand mixture during the refreshment process and act as a
flocculant.
Recommendations
1. Used water should be analysed, looking at the types and percentages of the
present ions (cations and anions).
2. If the previous analysis showed a positive result (as expected), deionized water-
tnstead of tap water could be used in the moulding machine.
4
ANNEX III
•1
SAND MOULDING STUDIES

IN
INDUSTRIAL PROGRESS CO.
SAND MOULDING STUDIES IN
INDUSTRIAL PROGRESS CO.
(A) ANALYSIS FOR BASIC SANDS
By studying two types of sand in the company, the first type is used for facing
sand and chemically bonded sand, the second type for backing and pit moulding.
(1) Grain Shape
The microscopic examination reveals that the two types used have nearly the
same shape, semispherical shape, but the second type has about 5-7% metal oxides
and solid materials with average size from 2-5 mm. These percent of course particles
lead to produce castings with rough surface.
(2) Fineness Content
Using standard method, the fineness contents, were determined for the three
types of sand used in the company.
Type of Sand Facing (1) Bcking (2)

Finess content 14.1% 25.2%
Types (1) and (2) have very high fineness contents, this deteriorates gas
permeability of the sand mixtures and produce casting defects.
(3) Grain Size Disfribution
The clay free sand samples were screened using a set of sieves belongs to the
series "R10" according to the standard methods.
From the results, the following parameter can be obtained:
Degrading of
Sand Type AFS Mean Particle Size
Ii niformity
Type (1) 54 0.315mm 57%
Type (2) 54.2 0.240 mm 47%
1
The results indicate that:
(1) The mean particle size is of medium size.
(2) The degree of uniformity is relatively small for the two types of sand
especially the second type, where the value of the degree of uniformity
must be within the range from 60-70%. These lower values highly
decrease the gas permeability of the sand mixture.
(3) AFS for the two types of sand is relatively high for making facing and
backing mixtures, whereas the optimum values must be between 35-45
to get good gas permeability.
(B) SAND MIXTURE
(1) Clay Content
Using standard method, the total clay content could be determined and by
using Metheline Blue Test, the active clay part was measured and accordingly the dead
clay part can be calculated. This can be shown in the following table:
Sand Type Total Clay Active Clay Dead Clay

Facing (1) 14.1% 12.5% 1.6%
Backing (2) 25.2% 17% 8.2%
From this table, the following results could be concluded
(a) Active clay content is very high especially in type (2), this percent must
be decreased to 9-10% for the local bentonite and to 7% for the
important one. An accurate percentage helps to get suitable properties,
by increasing bentonite and water additions in the mixture the moulding
parameter could be deteriorated.
(b) Dead clay content is very high in backing sand (type 2). These high
values cause a decrease in gas permeability and green thmpression
strength. This is the reason of increasing active bentonite in the sand
mixture to raise green compression strength.
2
(2) Specification of the Sand Mixtures
By re-using the sand of the two types 1 and 2 in our laboratory mixer with
different additions of water results show that
(a) Gas permeability
Due to the high clay content in the sand mixtures, the gas permeability is highly
decreased.
(b) Green compression strength (G.C.S.)
Types (1) and (2) of the sand mixtures have high G.C.S., 2 and 2.7 kg/cm2 at
6% water. This increase in G.C.S. is due to the high active clay content in the mixtures.
(c) Shatter index
The lower values of the two mixtures lead to form fraiable mould (of lower
moisture content). At higher moisture content the shatter increase but the gas
permeability decreases and also the riddel density. This leads to form hard moulds,
which makes difficulty when the pattern removed from the mould without any failure or
breakdown of the shaped edges of the mould cavity.
(d) Wet tesnile strength (W.T.S.)
The two types (1) and (2) of sand mixtures have very low W.T.S., where the
value limit must not be than 20 g/cm2 this decrease in W.T.S. is due to the high
increase of active and dead clay in the sand mixtures. These decreases in W.T.S. lead
to some casting defects such as buckling, scabs and rat-tails.
NOTES
(1) Return sand must be sieved to avoid any metal oxides or any solid
materials in the mixtures, using 0.63 mm opening sieve.
(2) Benonite contents must be controlled to avoid these problems.
(3) The sand system must be controlled to get good quality castings.
3
(2) Specification of the Sand Mixtures
By re-using the sand of the two types 1 and 2 in our laboratory mixer with
different additions of water results show that
(a) Gas permeability
Due to the high clay content in the sand mixtures, the gas permeability is highly
decreased.
(b) Green compression strength (G.C.S.)
Types (1) and (2) of the sand mixtures have high G.C.S., 2 and 2.7 kg/cm2 at
6% water. This increase in G.C.S. is due to the high active clay content in the mixtures.
(c) Shafter index
The lower values of the two mixtures lead to form fraiable mould (of lower
moisture content). At higher moisture content the shatter increase but the gas
permeability decreases and also the riddel density. This leads to form hard moulds,
which makes difficulty when the pattern removed from the mould without any failure or
breakdown of the shaped edges of the mould cavity.
(d) Wet tesnile strength (W.T.S.)
The two types (1) and (2) of sand mixtures have very low W.T.S., where the
value limit must not be lower than 20 g/cm2 this decrease in W.T.S. is due to the high
increase of active and dead clay in the sand mixtures. These decreases in W.T.S. lead
to some casting defects such as buckling, scabs and rat-tails.
NOTES
(1) Return sand must be sieved to avoid any metal oxides or any solid
materials in the mixtures, using 0.63 mm opening sieve.
(2) Benonite contents must be controlled to avoid these problems.
(3) The sand system must be controlled to get good quality castings.

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© 1995, Central Metallurgical Research and Development Institute.

SPONGE/CAST IRON TECHNOLOGY TRANSFER

ANNUAL TECHNICAL AND FINANCIAL REPORT

INTERNATIONAL DEVELOPMENT RESEARCH CENTRE (IDRC)

CENTRAL METALLURGICAL RESEARCH & DEVELOPMENT INSTITUTE

This research was carried out under grant from the

The research team of the Gent ral Metallurgical

III. ACTIVITIES PROGRAMMED AND EXECUTED 4

IV. OUTSTANDING RESULTS 8

Production of Ductile lron Castings in Selected Foundries

1. Rubex for MetaL Products 9

1. Seminar Conducted by CMRDI Research Staff for

2. Sand Moulding Studies in Industrial Progress Company

3. Sand Moulding Studies in Rubex for Metal Products

successfully carried out by the Central Metallurgical Research and Development

made from sponge iron.

castings were equivalent to those produced from conventional materials.

Different grades of ductile iron as well as abrasion-resistant, alloyed iron

casting were also successfully produced.

An economical assessment of the processes used showed that the cost of

foundries. Ductile iron rolls of different grades produced in weights up to 2.5

tons showed excellent performances in steel rolling mills.

The present project is concerned with transferring the resulting technology to

minimum of 10 small and medium size foundries around the country.

Approved date 23 May 1993.

Initiated date: 1 June 1993.

The period covered by this report 2nd Stage of actvities from

Prof. Dr. Adel Nofal project Leader

Dr. Ibrahim Moustafa Researcher

Eng. Mohamed Mourad Ass. Researcher

Eng. Massoud Ibrahim Ass. Researcher

Eng. Ramadan Ibrahim Research Engineer

Eng. Said Emam Research Engineer

Eng. Mohamed Ramadan Technician

Mohamed Mansour Technician

Magdy Moustafa Technician

Fareid Moustafa Technician

AshrafAbd El - Khalik Skilled Labourer

SaIlah Mansour Skilled Labourer

A group of 10 foundries was selected and divided into 4 main groups

From each foundry, 1 to 2 castings with special quality requirements

Together with the foundries personnel, a best practice technology for

- Alloy specifications, chemical composition and metallurgical features,

- Raw materials and charge calculations,

- Melting technique, furnace type, lining, sequence of melting and

- Moulding and core- making processes

The different properties of produced castings were evaluated as follows:

- surface quality and internal soundness,

The Mobile Foundry Laboratory ( MFL)

- Liquid metal temperature measurements.

provided an actual support to small and medium size foundries

- In addition, the sand moulding studies were performed in two

foundries representing the general trends in sand technology in

(1) Diagnostic Studies and Methodology

For the technology transfer of utilizing sponge iron instead of imported

foundries with technical capabilities to produce ductile iron were selected to

(2) Justification and Evaluation of Alternative Production System

The economics of the new technology was assessed in cooperation

2) A technical training course to use sponge iron with different additions

technology conditions of five foundries. These selected foundries are

(1) Rubex for Metal Products.