Melting behaviour of sponge iron in

induction furnace

K.N. GUPTA, A.M. PANDE AND A. K. VAISFI

National Metallurgical Laboratory, Jamshedpur-831007

Abstract

Sponge iron with its consistency of composition, lower content of tramp

elements and particularly low phosphorus and of sulphur has drawn the attention of
medium /large scale foundries for producing quality steel castings. It is one of the
alternative charge materials to scrap in induction furnaces. National Metallurgical
Laboratory has made an attempt to melt sponge iron in induction furnaces and
optimize its melting behavour. It is possible to use continuous charging arrangements
for melting of l(X)% sponge iron in induction furnace.

Introduction

Steel scrap is normally the feed stock for the production of steel in induction
furnace. The scarcity of the scrap coupled with its varying composition and irregular
size and supply is causing concern to the mini steel plants having induction furnaces.
Thus, vagaries of the scrap market has given an impetus to sponge iron as one of the
alternative charge materials to scrap. With deteriorating quality, fluctuating prices
and non-availability of scrap, the sponge iron with its consistency of composition,
lower content of tramp elements and particularly low phosphorus and sulphur has
drawn the attention of medium/large scale foundries for producing quality casting.

Attempts have been made in the past 1 1-6] to develop the technique for
producing steel by melting sponge iron in coreless induction furnace . Mostly
attention was paid towards the study of effect of slag formation , lining corrosion and
power consumption . In normal induction furnace operation , before the addition of
DRI, a liquid pool is made . Due to low conductivity of slag , it cools and forms a hard
crust on the topof the bath which hamper further feeding of DRi and its melting. This
problem can be partly overcome by adopting a continuous charging method and
intermittently deslagging [ Fig.11. Attempts have been made at NML to study the
melting behaviour of sponge iron in induction furnace and to optimize the melting
parameters for producing quality steel.

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 K.N.GUPTA , A.M.PANDE & A.K.VAISII

Experimental

Two varieties of sponge iron were melted in an induction furnace to investigate

(i) isothermal dissolution behaviour of single particle in basic and acid slags and, (ii)
the isothermal melting rate with different amounts of additions of sponge iron.
Sponge iron used in these experiments was produced from two different processes
namely, (i) coal based direct fired rotary kiln process at RDCIS (SAIL), Ranchi, and
(ii) Coal based indirectly fired vertical retort furnace process developed at NML
Jamshedpur. The chemical and physical properties of these two sponge iron used are
shown in Tables-I, II and III. A medium frequency coreless induction furnace
"Tocco" was used to investigate the melting behaviour of sponge iron. The experi-
mental study included the melting behaviour of individual particles and bulk, effect
of its density on the rate of melting and the variation of the melting rate of sponge iron
in unit weight of molten pool at various temperatures. The melting of sponge iron in
induction furnaces is beset with the difficulties of the requirement of a molten pool,
and formation of slag of the gangue. The slag being electrically non-conductive, was
melted only by the absorption of heat from the molten metal pool. Being much lighter,
it remains on the top of the pool after forming a solid crust which prevents the sponge
iron from coming in contact with the pool. The investigation was carried out to
optimize the rate of charging of sponge iron in coreless induction furnace for
continuous melting. From time to time slag was removed from the melt in order to
facilitate the maximum amount of sponge iron to the melt. The molten pool always
has a cover of slag, the isothermal dissolution behaviour of single particles was
studied in basic and acid slags, whose compositions are mentioned in figures 5 & 6.

In the present investigation about 70 percent of the liquid metal was taken out
from the furnace at each tap, leaving 30 percent as a pool of liquid metal to which DRI
was added and slag was removed intermittently.

Experiments were conducted to optimize the rate of melting initially at 1300°C

by varying the weight fraction of sponge charged to the molten pool. The first series
of experiments were carried out with both the types of sponge iron as indicated above
in high carbon molten pool at 1300°C. The results of this series of experiments
performed with a pool weight of 7 kgs. As both the varieties of sponge iron exhibited
identical pattern of melting rate , it was decided to continue further experiments with
one type of sponge iron i.e. NML sponge iron at different temperatures. Further
experiments were performed with a molten iron pool of 5 kg. at different tempera-
tures and the effect of various weight fractions of sponge iron on melting rate was
studied. The temperature of the molten pool was measured during the melting of
sponge iron by optical pyrometer and also by using Pt/I 3% Pt/ Rh thermocouple.

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

Result and Discussion

(i) Particulate Melting Characteristic of sponge iron

The melting time of individual particle is found to be affected by the type of

slag, size of the particle and its specific gravity. Figure-2 shows the average melting
time with one standard deviation of NML sponge iron in basic slag at 1300°C while
figure-3 shows the average melting time with one standard deviation of NML sponge
iron as well as SAIL sponge iron in a acidic slag at 1300°C. It clearly indicates that
the acidic slag facilitates melting, as melting time of NML sponge iron is reduced
from 7.8 seconds in basic slag to 7.1. seconds in acidic slag. The average melting time
of SAIL sponge iron is higher than that of NML sponge iron in acidic slag at 1300°C
due to its wider variation in particle size as shown in Table-2. Figure-4 shows the
regression of rate at melting upon the density of individual particle for both types of
sponge iron at 1300°C. It clearly indicates the beneficial effect of higher density on
the rate of melting of NML sponge iron. The essence of the particle wise experiments
when viewed in the light of its physico-chemical characteristic suggest that for best
results, the sponge iron should have close size range distribution, higher specific
gravity and higher metallization (+92%). Melting in acidic slags is better than in basic
slags.

(ii) Melting characteristic of Bulk Addition of Sponge Iron in Molten Pool

The rate of melting of sponge iron in a molten pool maintained at particular

temperature is a function of the rate of excess energy input over its liquidus point and
the particles available for being melted. From logical stand point, the maximum
melting rate is the optimization of these two parameters. Figure-5 displays the
variation of melting rate over a range of 0.05 to 0.25 weight fraction added at 1 3(X)°C
for both types of sponge iron. The highest melting rate of 0.07 weight fraction /minute
at 1 300°C suggests that the rate of excess energy input to a melt weight of molten iron
pool can assimilate 0.07 of its weight of sponge iron per minute. This forms the basis
of continuous charging and melting sponge iron in a molten pool. Both the types of
sponge iron exhibited similar trends. Further experiments were therefore carried out
with the NML sponge iron at 1300,1400,15(X) and 1600°C. Figures 6 and 7 show the
experimental results which indicate that

(i) Melting rate increased steadily with increasing temperature of the pool
at all additions.

(ii) The maximum melting rate is achieved at all temperature with the
optimum adjustment of the superheat of the pool with the available
sponge iron for melting

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

(iii) The melting rate maxima of 0.07, 0.14, 0.19 and 0.23 weight fraction
sponge iron/minute achieved at 1300°C, 1400°C, 1500°C and 1600°C
respectively indicate the possibility of continuous melting, while the
charging rate does not exceed the above figures.

(iv) The maximum melting rate increases steadily till 1500°C and after-
wards it slows down and becomes somewhat asymptotic beyond
1600°C. Figure-6 shows the variation of rate maxima with tempera-
ture.

Problems of Sponge Iron Melting in Induction Furnaces

For induction furnace melting, high metallized sponge iron with low gangue
content is required. Low iron oxide content is important for safety as well as for energy
consumption reasons. I f a large quantity of low metallized sponge iron is introduced into
a high carbon bath at a high tempeature, there is vigorous carbon boil. Such violent boil
hampers the process operation and can be extremely dangerous. Even when sponge iron
has high metallization, its feeding must be properly regulated to control the magnitude
of the reaction. The upper line in figure-8 shows the relation of the amount of the iron
oxide in the charged sponge iron as a function of the degree of metallization of sponge
iron, while the lower line shows the amount of iron oxide joining the slag, expressed as
percent of the charged sponge iron. It indicates that about 65 percent of the iron oxide is
reduced in the induction furnace a long as deoxidizing conditions prevail. Figure-9 shows
the effect of degree of metallisation on the energy consumption and clearly indicates that
energy consumption increases with the decrease in metallisation. This lowers the
capacity of the furnace, and, in addition requires the use of larger amount of carbon and
ferro-silicon to meet the chemical specification.

Proposed Modifications for the Continuous charging and Meltingof Sponge

Iron in Induction Furnace

Arrangements for continuous melting however faces the difficulty of cooling

of the slag and formation of crust. Therefore, arrangements were developed to overcome
the difficulties of continuous melting of 100% sponge iron at NML. The induction
furnace crucible was kept tilted to facilitate the withdrawal of slags during melting
(Figure- 10). The angle of tilting can be changed according to the volume of molten metal
pool. Thus a total capacity of the induction furnace could be utilised without causing any
problem. However, the slag characteristics Vs lining life of crucible, the suitable
frequency for the desired contour of the top surface, the avoidance of crust formation of
the slag are few of the points which require careful consideration before the adoption of
induction furnace.

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

Conclusion

(1) The experience of melting sponge iron in induction furnaces infers that the best
usage and melting of the sponge iron can be achieved if the particle size of the
sponge iron is in close range and its metallization is + 90%. The density of its
particle should be as high as possible.

(2) Even acidic slag facilitiates the melting of sponge iron.

(3) The melting rate increases with the rise in temperature . This requires careful
control particularly for the rate of charging of sponge iron in the metallic pool.

(4) It is possible to use continuous charging arrangements for melting of 100%

sponge iron in induction furnace by providing requisite modifications.

References

[I] V. Grumbrecht, D. Karsten and H .W.Lownie - Melting of Sponge Iron in

Coreless Induction Furnace, AFS Transactions, 1975.

[2] H.S. Pantke and C.Queens - Metallurgy of Sponge Iron Melting in Coreless
Induction Furnace - Proceedings of International Iron and Steel Congress,
Dusseldorf, 1974, V. II, Paper 3 .1.2.3.

[31 H.D.Pantke and C.Queen, Isimclt - A new Process for Steelmaking, Proceed-
ings of 2nd ILAFA Seminar on Direct Reduction, Porto Algere, Brazil, 1975.

[4] H.D.Pantke, and C. Queens , The Proceedings of Sponge Iron in Crucible

induction furnace , Stah and Eisen , 94 (1974) Nr.23, Nov.7, pp.1114-1120.

[5] W. Wenzel, F.R.Block and V.Grumbrecht, Meltdown of sponge iron in Induc-

tion Furnace, Stahl and Eisen 95, No.11, May 22, 1975, pp.496-502.

[6] E.Dotsch, Sponge Iron as burden in Foundry, Electrowacme International

32(1974) B5 D273-77 (In German).

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

Table-I : Chemical Analysis of Sponge Iron

Constituents Wt. % (SAIL) Wt.%o (NML)

Fe (Total ) 87.98 90.72

Fe (Metal ) 67.08 80.00
Metallization 76.24 88.18
Silica 2. 40 3.04
Alumina 1.56 0.28
Sulphur 0. 02 0.03
FcO (difference) 26.87 13.78

Table-2: Size Analysis of Sponge Iron

Size Wt. % (SAIL) Wt.% (NML)

+ 25 mm 3.5 0.0
-25mm + 19 mm 8.8 0.0
-19mm+12.5mm 37.5 5.1
-12.5 mm + 9 mm 43.7 56.2
-9mm + 6 mm 6.2 36.9
-6 mm 0.3 1.5

Table-3: Bulk Density and Specific Gravity of Sponge Iron

SAIL NML

Bulk density tonne/m3 (ASTMC-29-60) 1.809 1.957

Average apparent specific gravity 5.710 5.700

Average true specific gravity 6.310 6.281

Porosity % 9.51 9.25

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

Fig.) :Continuous charging tneduxl for direct reduced iron in to

induction furnace

16 S LA G
Si02 - 14.0%
FeO - 14.9%

0 Fe2 03 - 810`/0

Mn0 - 7.4'/0
X = 7.8 SECS. CaO - 39.7'/0
P2 05 - 2.1'/.

0 MgO - 6.0'/0
0 A12 0 3 . T 1 0 2 -6.8'/.
0 X - a- = 2.4 SECS. PARTICLE SIZE- - 19.6mm
2
TEMP 130c1C
1 2 3 4 5
PARTICLE NOS. -

Fig.2 : Average melting time and standard deviations (6) of NML

sponge iron basic slag at 13001C in medium frequency foreless
induction furnace

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 KN.GUPTA, A.M.PANDE & A.K.VAISH

SLAG
S10227.8
CaO 36.7
FeO K.9
20 Moo 2.64
0 - - NML PRI
•
• SAIL PRI
_---------x+r=- 16.4 Seconds -----
16

14
12
0 --X =12? ^ ----- ----
6 10 • x 9.6 Seconds
-------^-SfQng_s -------------
0 x =7.7sec0 0
6 O
-,- 4.54 Sec. 0 0 0
4
0
2

1 2 3 4 5 6 7 B 9 10 11 12 13 14 15 16 17
PARTICLE NOS. SIZE - -19 .6 nm

Fig.3 : Average melting time (x) and standard deviation of NML and
SAIL sponge iron in acidic slag at 1300 C in medium frequency
coreless induction furnace

O -NML SP I&E
4b 2
• - SAIL SFt7NGE

O
• NML
0
RM. 0.21D 40.71 SAIL

024D t Q?3 - 0 •

C ••
0.7

05

5.0 3.5 6.0 65

(D) DEAtS(TY(gm/cc) _

Fig.4 : Regression of rate ofmelting upon density in

basic slag at 1300 C

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 KN.GUPTA, A.M.PANDE & A.KVAISH

Fig.5: Optitn cation of melting rate of sponge iron in molten

iron (C-3.9, Si-1.7) 7.00 kg at 13001C in coreless induction furnace

Fig.6 : Optimisation of melting rate of sponge iron in molten metal

(C, 3.5 - 4.5, Si, 1.7-1.9) pool at different temperatures

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

Fig. 7 : Variation of the rate maxima with increasing tempeature

of molten pool in inductionfurnace

98 96 94 92 90 06 06
Degree of metallizaGon ;n %.

Fig.8 : Effect of the degree of metallization of DRI

on the amount of the iron oxide in the charge and
in the slag , expresed as %of the DRI charged

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 K.N.GUPTA, A.M.PANDE & A.K.VAISH

I000

800

600

400
98 96 94 92 90 88 ' 86
Degree of melallitotion, °/,

Fig. 9 : Effect of the degree of reduction of DRI

on the energy consumption during batch melting in a coreless
induuction furnace

Fig. 10 : Arrangements for continuous melting

of sponge iron in inductionfurnac e at NML

96