Cast iron production from sponge iron : final technical and financial report

The foundry industry in Egypt faces nowadays serious difficulties in securing the proper raw materials, especially those needed to produce molten metal. Both foundry grade pig iron and special types of pig iron; needed for ductile cast iron production are imported. In the meantime, classified steel scrap of the proper qualities is becoming a real scarcity. This report discusses the results obtained, on pilot scale, when using locally produced sponge iron - or directly reduced iron (DRI) as a main charge constituent in both induction furnaces as well as cupolas. that melting of sponge iron in both of furnaces It has been shown is technically and economically feasible. The pilot findings of this research gave much of the background needed to begin commercial applications in three Egyptian foundries. Sponge iron was utilized to produce either high purity pig iron in induction furnace, and that HPPI was later used for the production of ductile iron; or to directly produce ductile iron castings when added to a molten pool of Egyptian pig iron, steel scrap or foundry grade pig iron. On the pilot scale no difficulties were encountered in removal of excessive amounts of slag formed during melting - the influence on lining life was as well insignificant. On the other hand, the life time of lining of commercial scale induction furnaces was reduced by about 25% when using up to 30% sponge iron in the charge. This extra cost was, however, counterbalanced by the price difference of raw materials and the production cost of one ton of HPPI was still about 30% cheaper in favour of charges containing sponge iron..