Ferro Silicon Calcium Cored wire - Minex

Product Description
Calcium Silicide cored wire is souce of Calcium for steel industries, which is
used for Deoxidation, Desulphurization and Inclusion modification. Cored wire
is prepared by, high grade of CaSi granules or powder, which is filled in U
shaped steel sheath (Made of high quality of cold rolled steel strip), and this U
shapes steel sheath is closed tightly, so called overlapping craft, with help of
equipment. The encapsulated Calcium Silicide in steel sheath (called cored
wire) is injected into the steel melt with help of wire injection system with the
purpose of high recovery of Ca in steel than the virgin Ca / CaSi lumps
addition into the ladle. The powder specification of Calcium siliside, which is
used in cored wire, strip specification, & wire characteristics, is given below:
Chemical Composition of CaSi powder
Ferro Silicon Calcium Cored wire
Grade Powder Chemical Composition (%)
Ca Si Al (Max) C (Max) S (Max) P (Max) Fe (Min)
FeSiCa30 28-31 55-65 1.5 1 0.05 0.06 4.5
FeSiCa30+ 30-33 55-65 1.5 1 0.05 0.06 4.5
FeSiCa33 32-34 55-65 1.5 1 0.05 0.06 4.5
Powder Specification
Grade Density
(gm/cc)
Melting Point
(°C)
Size (mm)
FeSiCa30-33 2.5-2.7 1030 – 1200 -1.4 + 0.045
Wire Characteristics
Grade Diameter (mm Shape Powder Fill (gms/mt)
FeSiCa
9±0.5 Round
105±10
13±0.2 Round
230±10
16+0.2 Round
390±10
Strip Specification
Grade Diameter ( Thickness (mm)
mm
EDD IS –
513
9 ± 0.5
13 ± 0.2
0.30 – 0.35 ± 0.03
0.30 – 0.35 ± 0.03
16 ± 0.2 0.35 – 0.4 ± 0.03
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Coil Specification (Flipping Coil – Horizontal & Vertical)
Details
Powder
Weight
(MT)
Strip
Weight
(MT)
Net
Weight
(MT)
Length
(mtrs)
Internal
Diameter
(mm)
External
Diameter
(mm)
Height
(mm)
9 mm 13 mm 16 mm
F1-05 F1-10 F2-05 F2-10 F2-15 F2-20 F2-05
0.500 1.000 0.500 1.000 1.500 2.000 1.000
0.490 0.980 0.315 0.630 0.945 1.260 0.710
0.990 1.980 0.815 1.630 2.445 3.260 1.710
4760 9520 2172 4337 6521 8695 2631
650 650 650 650 650 650 650
1070 1190 1100 1200 1370 1420 1230
630 900 630 900 900 1000 900
Packing
Packing in flipping cage and mounted on
wooden / mild steel pallet and strapped with
pallet horizontally or vertically. All coils are
wrapped in stretch film & palletized
Application & Addition
Ferro Silicon Calcium Cored wire
Coil Identification
All coils are colour coded and fixed with a detailed
sticker clearly displaying details such as coil no.,
powder content, strip weight, gross weight density &
length. A fluorescent sticker displays the name of the
product in bold letters on the outer diameter of the
coil.
Handling
No metal sling, chain or rod is to be used across the
ID of the coil for handling as it may damage the coil.
Use only polyester, synthetic slings, fork lift/tractor
to handle the coil. The pallet is an integral part of the
coil and it is to be removed till the coil is consumed.
Shelf Life
Follow the shelf life period specified by MINEX
Storage & Safety
To be stored in dry & covered area away
from heat and moisture. Material Safety Data
Sheet can be supplied on demand
CaSi is universal deoxidizing, desulphurising and Inclusion
modifying agent used for manufacture every kind of steel as killed
plain carbon steel, low alloy steel, high grade alloyed steel,
stainless steel etc. (except low Si steel, where CaFe & CaFeAl
Cored wire is used to get same effect). In combination with
aluminium (FeAl / Al wire), it is used in cases where high demands
are made on the degree of purity and the surface quality of steel.
The addition of Calcium, and close control over the degree of
addition, is an important step in the steelmaking process. There
are various way to add calcium into steel melt. Usually calcium
silicide lumps added into bottom of the ladle and steel melt
(temperature 1500 - 1600°C) is poured into the ladle or Calcium
silicide powder can be added by powder injection method
through lance as shown in figure 1. :-
But it’s very costly and outdated process.
In ladle addition of Calcium silicide lumps, the recovery of Ca is very low. Due to lower density (2.5gm/cc) of
CaSi lumps its floats at the surface of melt and losses in oxidation and slag. Usually the recovery of Ca is only less
than 10%.
Whereas in cored wire Injection system the recovery of calcium is 15 – 30% with precise control of composition.
In CaSi cored wire, CaSi is encapsulated in steel sheath, when injected into steel it can go in depth of steel melt
as shown in
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In ladle addition of Calcium silicide lumps, the recovery of
Ca is very low. Due to lower density (2.5gm/cc) of CaSi
lumps its floats at the surface of melt and losses in
oxidation and slag. Usually the recovery of Ca is only less
than 10%.
Whereas in cored wire Injection system the recovery of
calcium is 15 – 30% with precise control of composition. In
CaSi cored wire, CaSi is encapsulated in steel sheath,
when injected into steel it can go in depth of steel melt as
shown in
figure2, where due to sufficient ferrostatic pressure,
calcium bubbles slowly raise to surface and react
efficiently in steel melt and also control of wire feeding
with help of wire feeder at desired speed ensures high
recovery, precise composition control and less fumes
generation. Thus the cored wire injection into the steel is
environmental friendly due to less fumes generation and
economical due to high recovery and less heat rejection.
Recovery of Ca in steel melt depends on various factors as
oxygen content & sulphur content into the melt,
temperature, wire injection speed etc...
Effects and Advantages
The following advantages have been reported from Ca – treatment as:
Ferro Silicon Calcium Cored wire
1. To improve steel castability in continuous casting (i.e., minimise nozzle blockage during casting with
consequential reduction in casting speed and possibly the formation of large aggregated alumina
clusters in the solidified product).
2. To get good surface quality and good internal slag cleanliness;;
3. To improve mechanical properties especially in transversal and through
thickness direction, by modifying manganese sulphides to globular Ca-Mn
sulphides, which are nearly non-deformable during rolling.
4. To improve steel machinability at high cutting speeds by forming a protective film on the tool surface that
prolongs the life of the carbide tool;;
5. To minimise the susceptibility of steel to reheat cracking, as in the heat-affected
zones (HAZ) of welds.
6. To prevent lamellar tearing in large restrained welded structures;; and
7. To minimise the susceptibility of high-strength low-alloy (HSLA) linepipe steels to hydrogen-induced cracking
(HIC) in sour gas or sour oil environment.
Fig. 2
Calcium % Yield Comparison Lumps vs Cored Wire
Ca Yield
(from CaSi
lumps)
0 5 10 15 20 25 30 35 40 45
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Ca Yield
(from Cored
Wire)
The addition rate of the Ca depends on the oxygen &
% Calcium Yield
sulphur concentration in steel and desired residual Ca
content in steel. The residual Ca content in steel should be
below the 20 ppm in order gets desired effect as Inclusion modification, improved castebility, reduced nozzle
clogging etc. And also, the addition of calcium to the steel in an amount ensuring that Ca/Al > 0.14 and Ca/S
> 0.7 leads to considerable decrease of the number and area fraction of long inclusions as well as their high
plastic deformability.

Ferro Silicon Calcium Cored wire
The following advantages have been reported from Ca – treatment as:
1. To improve steel castability in continuous casting (i.e., minimise nozzle blockage during casting with
consequential reduction in casting speed and possibly the formation of large aggregated alumina
clusters in the solidified product).
2. To get good surface quality and good internal slag cleanliness;;
3. To improve mechanical properties especially in transversal and through
thickness direction, by modifying manganese sulphides to globular Ca-Mn
sulphides, which are nearly non-deformable during rolling.
4. To improve steel machinability at high cutting speeds by forming a protective film on the tool surface that
prolongs the life of the carbide tool;;
5. To minimise the susceptibility of steel to reheat cracking, as in the heat-affected
zones (HAZ) of welds.
6. To prevent lamellar tearing in large restrained welded structures;; and
7. To minimise the susceptibility of high-strength low-alloy (HSLA) linepipe steels to hydrogen-induced cracking
(HIC) in sour gas or sour oil environment.
Figure - 3
Fig. 4 The sulpho-oxide inclusion;
1 – calcium aluminate,
2 – sulphide (Ca,Mn)S
As During solidication sulphur is selectively deposed at
grain boundaries in forms of various sulphides and their
solution (especially type II & III) and causes heterogeneity
of mechanical properties of nal products. Calcium change
the sulphur release mechanism in such a way that the
sulphur is bound to oxide or aluminate particles and not
deposed as sulphide inclusions at grain boundaries during
the steel solidication. see microstructure - Alumina inclusions
form calcium aluminates that can be as cores for
precipitating “oxysulphide” inclusions (Figure 4). The outer
layer contains calcium sulphide (or calcium sulphide with
little manganese) when sulphur content is low or calciummanganese
sulphide when sulphur content is higher. The
mechanism and stage of formation of the oxysulphides is
not fully known,
but the favourable inuence of these complex inclusions
for many products is well known i.e. improving the machinability
of hardening and tempering as well as casehardening
steels. The formation of oxide layer on the tool is optimized
and results in longer tool life and in possibility to use
higher cutting speeds. Better surface quality of the product
is also attained. In addition, good castability is an important application of Ca-treatment.
For some products, however, the Ca-treatment and hence modication of inclusions must be avoided. For
instance, well deformable silicate type inclusions are desirable for wire materials and undeformable inclusions
should be avoided. In general, the properties of nal products must be thoroughly considered when
choosing the proper ladle treatment.
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