In this article, we will introduce the flux product produced at Çimsa to be used to increase efficiency in the Iron- steel industry.
What Is Calcium Aluminate Cement CA Flux?
Casting chemicals used to remove oxidized compounds, impurities, and undesired elements inside the liquid metals such as aluminum, copper, zinc, and magnesium from the liquid metal bath and to make these metals clean metals suitable for casting as well as to cut their contact with the atmosphere are called flux. CA Flux is a metal with melting properties that enables removal of pollutive materials from the system together with slag in the iron-steel sector. It has been designed as an environment-friendly product, developed specifically for Iron-Steel industry to increase production efficiency and to help with the purification of molten steel at 1375˚C. With its special phase structure, Flux increases the efficiency of steel production and brings long-term benefits. It has a low melting point. It provides a stable phase structure and chemistry for steel processing. Special particle sizes are provided depending on the needs.
Synthetic slag makers with Calcium Aluminate base are a type of auxiliary material for the refining process during steel production. Its production is conducted through milling at the correct ratio to provide a homogeneous mixture for calcium aluminate production. Later it is sintered or melted in the furnace. The targeted mineral composite is CA, CA2, C3A and C12A7.
Image 1: CA Flux Compound
Where To Use CA Flux?
It is used in the secondary steel production in the iron-steel sector, its intended use is to reduce temperature and enable impurities in the steel to gather in the slag at the top.
Image 2: The flux layer which reduces production temperature between the slag at the top and iron at the lower part to help with purification
It is a material added during the melting process and reduces the melting point of the melted material. It decreases viscosity of slag phase. It decreases the activity of certain components of the slag and makes them stable. Therefore, liquid metal’s fluidity increases. Limestone and dolomite are generally used as melters in iron production.
Usage of CA Flux:
- Isdemir uses 10,000-15,000 tons of CA Flux annually in the production of high-purity steel.
- The estimated consumption in Türkiye is as follows:
- Isdemir (min. 10,000 – max. 15,000 tons/year)
- Erdemir (min. 200 tons/year)*
- Tosyalı (min. 3,500 – max. 9,000 tons/year)*
What is the Importance of Calcium Aluminate Cement CA Flux?
Flux is a product between CAC 40 and CAC 50 clinker. It provides advantages such as fast hardening, early high strength, controlled expansion, and resistance against shrinkage. It has been designed as an environment-friendly product, developed specifically for Steel industry to increase production efficiency and to help with the purification of molten steel at 1375˚C. For Flux, the humidity covers the surface of the binder as the pre-hydration increases and causes reactive phases to react and thus leading to performance loss in the end product. CAC’s phase structure and content are important to provide long-term reactivity. The primary role of Flux is to make the impurities found in iron ores to melt easier to pass on to the slag. Some elements are reduced in a way completely similar to iron and melt inside the iron or they enter into a chemical recombination with the iron. Some other elements found in combined with iron in the raw material cannot be removed from the iron without another material to prefer to metal to recombine. The secondary role of Flux is to provide this material which these elements or compounds will prefer to recombine with and to ensure metal to become free.
References:
- R. Jolly, B. Touzo. Alloyed Calcium Aluminates Flux: Optimised Formulation for an Efficient Slag Conditioning in Ulc Production: Kerneos Technical Paper.
- Using Of Calcium Magnesium Aluminate Flux with High Mgo Content to Improve Secondary Steel Ladle Life Time. Paulo César Evangelista, Remy Jolly, Christoph Wöhrmeyer, Christian Brüggmann. 2011.
- Calcium Aluminate Cement: Issues to Take into Consideration
