Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking

Jaleel Kareem Ahmad

doi:doi:10.11648/j.ijmsa.s.2015040201.11

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Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking

Jaleel Kareem Ahmad

Published in International Journal of Materials Science and Applications (Volume 4, Issue 2-1)

Received: 19 October 2014 Accepted: 2 November 2014 Published: 3 November 2014

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Abstract

No problem with the melting of new carbon – free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon – free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life ( ~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron ( contain 5% wax according to Jaleel waxing process) according to HYL costs system.

Published in	International Journal of Materials Science and Applications (Volume 4, Issue 2-1) This article belongs to the Special Issue Steel and Direct Reduced Iron (sponge Iron) Industry
DOI	10.11648/j.ijmsa.s.2015040201.11
Page(s)	1-6
Creative Commons	This is an Open Access article, distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution and reproduction in any medium or format, provided the original work is properly cited.
Copyright	Copyright © The Author(s), 2014. Published by Science Publishing Group

Keywords

Direct Reduced Iron, Wax, Steel, Electric Arc, Furnace

References

[1]	Dr. Jaleel Kareem Ahmed and Eng. Haidar Jaleel Kareem, Water Hydrogen use in DRI-Industry, Arab Steel – No.331 Sempteber-2003.
[2]	J. A. T. Jones, B. Bowman, and P. A. Lefrank, Electric Furnace Steel Making, Arab Steel No. 331 Sept. 2003.
[3]	Dr. Jaleel Kareem Ahmmed, 7th International Iron and Steel Conference 2004, Stimulating and Encouraging Reasons for Future Expansion in DRI and Steel in Iraq, Arab Steel No. 342 September 2004.
[4]	Dr. Jaleel Kareem Ahmed, Carburizing of Steel, Iraqi patent No. 1480.
[5]	V. E. Pirozhnikov, "Effect of Slag on thermal processes in the Electric Furnaces", Stal, March 1967, PP222-224.
[6]	Juan Celada S., Technical Vice-President, AlFa Steel Division, June 1978.
[7]	Warth, the Chemistry and technology of Waxes, Reinhold Publishing Corporation, New York, 1956.

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APA Style

Jaleel Kareem Ahmad. (2014). Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking. International Journal of Materials Science and Applications, 4(2-1), 1-6. https://doi.org/10.11648/j.ijmsa.s.2015040201.11

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ACS Style

Jaleel Kareem Ahmad. Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking. Int. J. Mater. Sci. Appl. 2014, 4(2-1), 1-6. doi: 10.11648/j.ijmsa.s.2015040201.11

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AMA Style

Jaleel Kareem Ahmad. Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking. Int J Mater Sci Appl. 2014;4(2-1):1-6. doi: 10.11648/j.ijmsa.s.2015040201.11

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@article{10.11648/j.ijmsa.s.2015040201.11,
  author = {Jaleel Kareem Ahmad},
  title = {Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking},
  journal = {International Journal of Materials Science and Applications},
  volume = {4},
  number = {2-1},
  pages = {1-6},
  doi = {10.11648/j.ijmsa.s.2015040201.11},
  url = {https://doi.org/10.11648/j.ijmsa.s.2015040201.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmsa.s.2015040201.11},
  abstract = {No problem with the melting of new carbon – free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon – free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life ( ~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron ( contain 5% wax according to Jaleel waxing process) according to HYL costs system.},
 year = {2014}
}

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TY  - JOUR
T1  - Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking
AU  - Jaleel Kareem Ahmad
Y1  - 2014/11/03
PY  - 2014
N1  - https://doi.org/10.11648/j.ijmsa.s.2015040201.11
DO  - 10.11648/j.ijmsa.s.2015040201.11
T2  - International Journal of Materials Science and Applications
JF  - International Journal of Materials Science and Applications
JO  - International Journal of Materials Science and Applications
SP  - 1
EP  - 6
PB  - Science Publishing Group
SN  - 2327-2643
UR  - https://doi.org/10.11648/j.ijmsa.s.2015040201.11
AB  - No problem with the melting of new carbon – free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon – free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life ( ~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron ( contain 5% wax according to Jaleel waxing process) according to HYL costs system.
VL  - 4
IS  - 2-1
ER  -

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Author Information

Jaleel Kareem Ahmad

College of Materials Engineering, Babylon University, Babylon, Iraq

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APA Style

Jaleel Kareem Ahmad. (2014). Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking. International Journal of Materials Science and Applications, 4(2-1), 1-6. https://doi.org/10.11648/j.ijmsa.s.2015040201.11

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ACS Style

Jaleel Kareem Ahmad. Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking. Int. J. Mater. Sci. Appl. 2014, 4(2-1), 1-6. doi: 10.11648/j.ijmsa.s.2015040201.11

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AMA Style

Jaleel Kareem Ahmad. Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking. Int J Mater Sci Appl. 2014;4(2-1):1-6. doi: 10.11648/j.ijmsa.s.2015040201.11

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@article{10.11648/j.ijmsa.s.2015040201.11,
  author = {Jaleel Kareem Ahmad},
  title = {Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking},
  journal = {International Journal of Materials Science and Applications},
  volume = {4},
  number = {2-1},
  pages = {1-6},
  doi = {10.11648/j.ijmsa.s.2015040201.11},
  url = {https://doi.org/10.11648/j.ijmsa.s.2015040201.11},
  eprint = {https://article.sciencepublishinggroup.com/pdf/10.11648.j.ijmsa.s.2015040201.11},
  abstract = {No problem with the melting of new carbon – free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon – free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life ( ~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron ( contain 5% wax according to Jaleel waxing process) according to HYL costs system.},
 year = {2014}
}

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TY  - JOUR
T1  - Melting of a New Carbon –Free Waxed Sponge Iron in Electric Arc Furnace (EAF) for Steelmaking
AU  - Jaleel Kareem Ahmad
Y1  - 2014/11/03
PY  - 2014
N1  - https://doi.org/10.11648/j.ijmsa.s.2015040201.11
DO  - 10.11648/j.ijmsa.s.2015040201.11
T2  - International Journal of Materials Science and Applications
JF  - International Journal of Materials Science and Applications
JO  - International Journal of Materials Science and Applications
SP  - 1
EP  - 6
PB  - Science Publishing Group
SN  - 2327-2643
UR  - https://doi.org/10.11648/j.ijmsa.s.2015040201.11
AB  - No problem with the melting of new carbon – free waxed coated sponge iron (Jaleel's process) for producing different steel alloys. Coated wax: (1) acts as inhibitor for inhibition of reoxidation of sponge iron. (2) provide the required carbon for reduction iron oxide as well as a balance for the chemical composition of steel. (3) provide part of the heat required for the reduction. (4) acts as a refiner for the steel via hydrogen formation in the slag which attacks impurities. Economic study was done show that (1) about 8-10% reduction in the electric energy consumption with the new carbon – free waxed sponge iron comparing with that of normal sponge iron under the same melting conditions. (2) long life ( ~ 20-25% more) for carbon electrode in the case of the new material melting comparing with that of normal sponge iron due to the reducing atmosphere created from the wax combustion during melting. (3) chemical analyses for produced steel show no traces of sulfur and phosphorous remain after melting. (4) calculation shows that there is a 5% reduction in the total steel cost production in case of using 50% sponge iron ( contain 5% wax according to Jaleel waxing process) according to HYL costs system.
VL  - 4
IS  - 2-1
ER  -

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