REPORT ON RECARBURIZER FOR IRON

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 Content

Page No.
No. Subject
(1-28)
1 Carbon additive/ Recarburizer 4
2 Classification of carbon additives 4
2.1 Graphitized carbon additives 5
2.1.1 Graphite 5
2.1.1.1 Natural graphite 5
2.1.1.2 Synthetic graphite 5
2.1.2 Graphitized petroleum coke 6
2.2 Non-graphitized carbon additives 6
2.2.1 Coke 6
2.2.2 Calcined petroleum coke 7
2.2.3 Acetylene coke 7
2.2.4 Pitch coke 7
2.2.5 Metallurgical coke 7
2.2.6 Anthracite 8
2.2.7 Electrically Calcined Anthracite 8
3 Carbon additive index 8
3.1 Fixed carbon, ash, volatile matter 8
3.2 Sulfur 8
3.3 Nitrogen content 8
4 The properties and morphology of the carburizers 10
5 Choice of recarburiser 12
Specifications of good recarburizer and choice of right
6 13
recarburizer
Choice of right recarburizer recarburizer for cast iron
7 with induction electric furnace and efficient way of using 14
recarburizer
Choice of right recarburizer based on recarburizer size
8 15
and capacity of furnace
9 Use of recarburizer correctly 16
The attention need to pay in process of recarburizer and
10 16
scrap steel

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 Use of silicon carbide and recarburizer in cast iron
11 17
smelting
How to improve the absorption rate of graphitized
12 18
petroleum coke in furnace
13 Summary 19
14 Case Study 20

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 1. Carbon additive/ Recarburizer
The recarburizer is a material used to increase the carbon content. The main component is carbon.
There are many materials that can be used as a recarburizer. Commonly used are coke and
anthracite, calcined petroleum coke, graphitized petroleum coke, and graphite (artificial graphite,
natural graphite) and mixtures made from such materials.
The carbon additive is used to reduce the oxygen content in the molten iron mainly during metal
smelting and improve the mechanical properties of the casting. In the new synthetic cast iron
smelting process, the amount of scrap steel used is greatly increased. By adding a carbon additive
to adjust the carbon content of the molten iron, the production cost is greatly reduced while
ensuring the quality of the molten iron.

2. Classification of carbon additives

According to the existence form of carbon atoms, carbon additive can be divided into
a) Graphitized carbon additive
b) Non-graphitized carbon additive

Table1: Chemical composition of the carburizers

c)
d)
e)
f)

Typical carburizers’ chemical composition are shown in Table 1. Carbon content (C) in samples
varies from 85% for the natural graphite to 99.35% for the synthetic graphite.
Reliable carbon yields are achieved with high and constant carbon levels in the recarburizer, proper
size grading, and a high dissolution rate in the steel. The maximum size of rapidly dissolving
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recarburizers is usually 12 to 16 mm, while that of more slowly dissolving materials is between 1
and 6 mm. The lower limit is about 0.1 to 0.2 mm because excessive dust can result in erratic
carbon yields.
2.1 Graphitized carbon additives
Graphitized carbon additive mainly includes graphitized petroleum coke and graphite electrode.
Graphitized petroleum coke carbon additive is the most widely used in the foundry industry. The
production process is to convert the raw material petroleum coke in a graphitization furnace
through a high temperature of 2200-2600 °C, so that the carbon crystallization of the petroleum
coke amorphous layer structure is transformed into the high-temperature heat treatment process of
the three-dimensional ordered graphite crystal, that is, through the graphitization process, reaches
the graphitization state.
2.1.1. Graphite: Graphite is an allotrope of elemental carbon. Each carbon atom is connected with
three other carbon atoms (multiple hexagons arranged in a honeycomb shape) to form a covalent
molecule by covalent bonding. Graphite and carbon products have excellent performance, are
increasingly used, and the production capacity and benefits are growing rapidly. Graphite is mainly
divided into natural graphite and artificial graphite.
2.1.1.1. Natural graphite
Natural graphite can be divided into two types:
a) Microcrystalline or flake graphite
b) Amorphous graphite
Microcrystalline graphite has a high ash content and is generally not used as a carbon reinforcer
for cast iron. There are many varieties of flake graphite. High-carbon flake graphite needs to be
extracted by chemical methods, or heated to high temperature to decompose and volatilize the
oxides. This flake graphite has low yield and high price, and generally does not act as a
recarburizer; low carbon scales Graphite has a high ash content and should not be used as a
recarburizer; it is mainly used as a carbon reinforcer for medium carbon graphite, but it is not used
in large amounts.
Both types being low in sulphur and nitrogen. The crystalline type has a particle size smaller than
1 mm, and has to be agglomerated unless it is injected into the ladle. The amorphous graphite is
found in larger pieces, and can have a water content of up to 4 per cent; it has to be dried before
use.
2.1.1.2. Synthetic graphite
Among the above various recarburizing agents, the best quality is artificial graphite. The main raw
material for the manufacture of artificial graphite is powdered high-quality simmered petroleum
coke, in which asphalt is added as a binder, and a small amount of other auxiliary materials are
added. After the various raw materials are combined, they are press-formed and then treated in a
non-oxidizing atmosphere at 2500 to 3000 ° C to be graphitized. After high temperature treatment,
the ash, sulfur and gas contents are greatly reduced. Due to the high price of artificial graphite

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products, the artificial graphite breakers commonly used in foundries are mostly cut when
manufacturing graphite electrodes.
Recycled materials such as chips, used electrodes and graphite blocks to reduce production costs.
In the smelting of ductile iron, in order to make the metallurgical quality of cast iron superior, the
carbon-reducing agent should be the first choice of artificial graphite. For this reason, it is better
to purchase scrap electrodes from nearby companies that use electric arc furnace steelmaking or
electrolytic aluminum production enterprises, and crush them to the required particle size.
2.1.2. Graphitized petroleum coke: Graphitized petroleum coke refers to the high-temperature
graphitization of petroleum coke. Under the high temperature of 3000 °C, the carbon molecular
form in the petroleum coke is changed from an irregular arrangement to a hexagonal uniform
arrangement. The agent is most easily decomposed in molten iron.
Characteristics of graphitized recarburizer
1) The low-sulfur graphitization recarburizer has a high decomposition rate and a high
absorption rate, and can reach more than 90%.
2) High carbon, low sulfur, low nitrogen, and extremely harmful components.
3) Adding graphite nucleus to molten steel and molten iron, more uniform and finer
distribution in molten steel and molten iron, so that the performance is more excellent and
stable.

2.2 Non-graphitized carbon additives

The non-graphitized carbon additive mainly includes: calcined petroleum coke, coal carbon
additive, etc., calcined petroleum coke refers to petroleum coke heated at 1200-1500 ° C high
temperature, the treatment temperature is low, and the crystal structure has not changed. Due to
the high ash content and volatile matter, coal-based carbon additive is rarely used in electric arc
furnace smelting.
The indicators for measuring the quality of carbon additives are fixed carbon content, sulfur,
volatile matter, ash, nitrogen content and water. After high temperature graphitization, the
graphitized carbon additive has a much lower sulfur and nitrogen content than the non-graphitized
carbon additive.
2.2.1. Coke: Coke is a type of solid fuel. It is obtained by dry distillation of coal under high
temperature conditions of about 1000 °C. The main component is fixed carbon, followed by ash,
and contains less volatile matter and sulfur. It has silver-gray, metallic luster. It is hard and porous.
In addition to a large amount of coke is needed for iron, non-ferrous metal smelting (metallurgical
coke). The coke used in foundry, chemical industry, calcium carbide and ferroalloys has different
quality requirements. For example, for casting coke, it is generally required to have large particle
size, low porosity, high fixed carbon and low sulfur content; coking for chemical gasification is
not strict with strength, but requires good reactivity, high ash melting point, and coke requirement
for calcium carbide production. Try to increase the fixed carbon content.

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2.2.2. Calcined petroleum Coke: Calcined petroleum coke is a widely used recarburizer, which is
obtained by calcining petroleum coke. Petroleum coke is a by-product of refined crude oil.
Residual oil and petroleum asphalt obtained by vacuum distillation or vacuum distillation can be
used as raw materials for petroleum coke, and then coke is obtained to obtain raw petroleum coke.
The annual production of American petroleum coke is about 30 million T. The raw petroleum coke
has high impurity content and cannot be directly used as a recarburizer. It must be calcined first.
Raw petroleum coke has spongy, needle-like, granular and fluid states.
1) Sponge petroleum coke is produced by delayed coking. Because of its high sulfur and metal
content, it is usually used as a fuel for calcination and as a raw material for calcined
petroleum coke. The calcined plum cotton coke is mainly used in the aluminum industry and
as a recarburizer.
2) The acicular petroleum coke is obtained by a delayed coking process using a raw material
having a high content of aromatic hydrocarbons and a low impurity content. This coke has
a needle-like structure that is easily broken, sometimes referred to as graphite coke, and is
mainly used for the manufacture of graphite electrodes after calcination.
3) Granular petroleum coke is a hard granule. It is a raw material with a high content of sulfur
and bitumen. It is produced by delayed coking and is mainly used as a fuel.
4) The fluid petroleum coke is obtained by continuous coking in a fluidized bed. It is in the
form of fine particles, has no directional structure, high sulfur content and low volatile
content.
The burning of petroleum coke is to remove sulfur, moisture, and volatiles. The raw petroleum
coke is burned at 1200 - 1350 ° C to make it substantially pure carbon. Medium sulphur or regular
aluminium coke is made from a direct residue of crude-oil distillation, and is used mainly for
electrodes in the production of aluminium. The sulphur content can be up to 2 %. The more
expensive low-sulphur needle coke is made from very pure tar and contains about 0.2 % sulphur.
2.2.3. Acetylene coke: Acetylene coke and carbon black are materials that can be categorized as
high-purity carbon sources. The coke is obtained by confined exothermic cracking of acetylene,
and carbon black is manufactured by carefully controlled partial combustion of hydrocarbons,
mainly heavy aromatic oils that were synthesized during the processing of crude oil or coal. For
recarburizing purposes, the fine powders are agglomerated with organic binders that bum off
during the calcining after palletization or extrusion. The carbon contents of the final products are
over 99 %.
2.2.4. Pitch coke: Pitch coke is produced in modified coke ovens that are charged with hard pitch,
which is derived from coke-oven tar. The charge is held at approximately 1300°C for about 20
hours in the ovens.
2.2.5. Metallurgical coke: This material is made by the destructive distillation of coal in coke
ovens at a temperature of about 1300°C. Carbonization proceeds over a period of about 16 hours,
and the final temperature of the coke is approximately 1050°C. It is usually water-quenched when
being discharged from the furnace, and must be dried before being used as a recarburizer. The
recarburizers that are mostly used at present in South Africa are synthetic graphite for critical

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applications and calcined anthracite for general-purpose use. The required quality of a recarburizer
is a function of the performance expected. If the specification for chemical analysis is not stringent,
carburizers containing about 80 to 90 % fixed carbon can be used. However, when narrow carbon
ranges are specified, recarburizers with 98 to 99 % carbon are generally applied. With the
increasingly stringent specifications for steel properties, it is usually a better option to use the more
expensive, high-purity recarburizer than to risk a heat being scrapped because of an erratic carbon
yield from a low-cost and low-purity material.
2.2.6. Anthracite: Anthracite is a hard, dense and high-gloss coal mine. The main applications of
anthracite lump coal are chemical fertilizer (nitrogen fertilizer, synthetic ammonia), ceramics,
manufacturing forging and other industries; anthracite coal is mainly used in the metallurgical
industry for blast furnace injection (blast furnace coal mainly includes anthracite, lean coal, lean
coal and gas coal).
2.2.6. Electrically Calcined Anthracite: Low-sulphur anthracite with a grain size of about 12 to
25 mm is charged into a shaft furnace and heated to above 1800°C between two vertically placed
electrodes. The residence time is about 4 hours, during which some graphitization takes place.

3. Carbon additive index

3.1. Fixed carbon, ash, volatile matter
The fixed carbon of carbon additive is different from the carbon content. The fixed carbon value
is calculated based on the moisture, volatile matter, ash and sulfur content of the sample, and the
carbon content can be directly detected by the instrument. The fixed carbon content is high and
the ash content is low, so the carbonization effect is better. The high ash content in the carbon
additive generates a large amount of soot and slag during the smelting process, increases energy
consumption, and increases the labor intensity of the slag.
Fixed carbon is defined as
Cfix= 100 % - (% M + % VM + % A)

where M is moisture, VM is volatile matter, and A is ash.

Good carburizer should have high carbon content (>95%), low sulfur content (<0.3%), volatile
parts (<1%) and should not contain more than 0.9% of moisture. The impurities in the carburizer
decrease carbon assimilation rate, increase slag volume and cause deterioration of produced alloys
quality. The process rate and mass transfer coefficient are decreased, too. Due to higher carbon
dissolution rate in cast iron, the use of the synthetic graphite is better, but its much higher cost
causes the necessity of cheaper anthracite and petroleum coke based carburizers use.

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The important issue in recarburization process is carbon assimilation by liquid metal. It depends
on many factors i.e. recarburization method, liquid bath temperature, recarburized alloy chemical
composition and type of carburizer, too. For the melts, the recarburization efficiency can be
calculated for various types of carburizers added to the solid charge. Stability of the melting
conditions and chemical composition of the charging materials causes that decisive influence on
the recarburization efficiency has in this situation carburizer type. For the particular melts the
recarburization efficiency can be calculated according to the formula:
𝐶𝐾 − 𝐶 𝑝
E = 𝑀𝑚 × 100%
𝑀𝑛 . 𝐶𝑛

where: Mm = metallic charge mass, Mn = carburizer mass, Cn = carbon content in carburizer, Cp =

initial carbon content in charging materials or liquid metal (before recarburization), Ck = final
carbon content after recarburization process, ∆C = (Ck-Cp) = carbon increase in liquid bath after
carburizer introduction.
3.2. Sulfur
The sulfur content of ordinary calcined coke has a relatively high grade, generally less than 3% of
sulfur to 0.1%, and the sulfur content of graphitized carbon additive is generally less than 0.05%.
In ordinary cast iron, sulfur element has stable cementite and prevents the expansion of
graphitization. In the production of ductile iron and vermicular graphite iron, a graphitized carbon
additive with low sulfur content should be used. If the sulfur content is too high, the ball will be
affected. The effect is to consume more spheroidizing agent and increase the production cost; the
calcined petroleum coke carbon additive is used in the production of some gray iron castings
because of the lower calcination temperature and higher sulfur content, generally less than 1%.
3.3. Nitrogen content
Nitrogen content is an important indicator of the quality of carbon additive. In general, when the
foundry purchases the carbon additive, the first is to pay attention to the price of the carbon
additive; the second is the fixed carbon, sulfur, ash, volatile matter, and moisture content in the
carbon additive, and less attention is paid to the nitrogen content. Ordinary calcined petroleum
coke carbon additive, the calcination temperature is low, and the nitrogen and sulfur contents are
high. When producing gray iron castings, the scrap steel itself will bring in a part of nitrogen. If
the scrap is added in a large proportion, the amount of carbon additive will increase accordingly.
If ordinary calcined carbon additive with high nitrogen content is used then it need to add in the
molten iron in the furnace. The nitrogen content will increase significantly. Excessive dissolved
nitrogen in the molten iron hinders graphitization, increases the stability of the carbide, promotes
the formation of D-type graphite, improves the hardness, and deteriorates the processing properties
of the casting.
For gray cast iron, the proper amount of nitrogen can shorten the length of the graphite sheet,
increase the degree of bending, passivate the end, reduce the aspect ratio, stabilize the pearlite of
the matrix, refine the grain structure and improve the tensile strength of the casting. And the role

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of hardness. According to the data, when the iron is N>0.012%, there is a possibility of nitrogen
hole defects in the casting. Nitrogen pores are commonly found in the interior, surface or near
surface of castings. They are round, rectangular and irregular in shape and are one of the common
defects in casting production. The graphitized carbon additive is subjected to high-temperature
desulfurization and denitrification treatment, and the content of nitrogen and sulfur is very low.
Factors affecting the absorption rate of carbon additive: The factors affecting the absorption
rate of carbon additive are mainly the way of adding carbon additive, the chemical composition of
molten iron, the temperature of molten iron, and the particle size of carbon additive.
Recarburizers are almost invariably added to the ladle either during tapping or during secondary
treatment, and vigorous reactions with steel can occur when excessive moisture and residual
volatile matter are present in the material. A maximum of 1 % each is usually specified. Mineral
matter present in the recarburizer decreases the carbon yield, presumably by forming a liquid film
upon melting and consequently preventing the carbon and iron from coming into intimate contact.
Part of the sulphur and nitrogen in the recarburizer is transferred to the steel during the reaction,
the quantities adsorbed depending on the amount of free oxygen in the steel. Trials with rimming
and semi-killed steels showed that the yield of sulphur and nitrogen from a carbon source tended
to be similar to that of carbon, and concentrations in the melt increased proportionally with the
carbon content in the steel.

4. The properties and morphology of the carburizers

From the crystalline structure order point of view two groups can be distinguished among the
carbonaceous materials. The first group, which are polycrystalline graphite materials, the main
structural components are graphite crystallites. The second group are less ordered carbonaceous
materials and their main structural components are built of graphen layers packets, approximately
parallel but randomly ordered along perpendicular to their surface direction and such appearance
is so-called turbostratic crystallite. Figure 1 shows the surface morphology of theanthracite (A)
cupola coke (KO) natural graphite (GN) charcoal (WD) synthetic graphite (GS) and petroleum
coke (KN).
According to Fig. 1 the surface morphology of both anthracite (a) and graphite (c) have similarity.
In small magnification, the surface looks almost smooth and compact. In many places the mineral
inclusions appear, which contain generally Mg, Ca, Fe, S and Al and C and O. With higher
magnifications (20kx) the pores appear – some of them are of spherical shape. The flakes or the
leaves of the graphite were not observed, however, it is visible that the sample is not compact and
the pores and crevices are parallel in many places.

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 (a) (b)

(d)
(c)

(e) (f)

Fig. 1 Surface morphology of (a) anthracite, A (b) cupola coke, KO (c) natural graphite, GN (d)
charcoal, WD (e) synthetic graphite, GS and (f) petroleum coke, KN

On Fig. 1(e) the synthetic graphite (GS) morphology was presented. Irregular surface shape is
visible even for 2kx. Empty areas (pores) of various shapes and size occur between curved layers.
For greater magnifications it could be observed that cracks and crevices are parallel, while the
whole sample consists of much defected layers – graphite leaves, in which densely appear small
mineral inclusions. Distinct from graphite flakes, which are flat (Fig. 1(c)), the graphite leaves
may be strongly curved. Their edges are irregular and fuzzy. On Fig. 1(f) the petroleum coke
morphology (KN) was presented. The chosen surface areas vary one from another much. Some of
them are built of layers of parallel situated folds and graphite leaves. In some parts of analyzed
sample, especially during the low magnification observation, the surface is smooth but cracked.
On higher magnifications they are visible coiled significantly fuzzy graphite leaves which create

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coils. In their middle and between them the empty spaces remain – the pores. On Fig. 1(b) the
cupola coke morphology was presented (KO). On high magnifications the graphite flakes may be
observed similarly as for natural graphite. For the charcoal (Fig. 1(d)) the regular round pores are
visible on high magnifications.

5. Choice of recarburiser
The selection of a recarburiser always depends on the produced iron alloy. Ductile graphite iron
(GGG / GJS), cast iron with vermicular graphite (CGI) and special steel grades require a low sulfur
content.
For grey iron (GG / GJL) normally a recarburiser with a medium sulphur content is fully sufficient
(see enclosed table). To determine the carbon content, at least one sample should be extracted from
the molten iron for chemical analysis.

Type of Field of Solubility

Properties / Advantages / Disadvantages
recarburiser application 1–6
Graphite: crystalline carbon
High purity, synthetic
High C content, very good solubility, low N and H
raphite (i.e. Ultra High all iron alloys 1
content
Power-E-Graphite)
Synthetic graphite
High C content, very good solubility, low S, N, ash
E-graphite graphitised all iron alloys 1
content
Petroleum coke
iron alloys with an The higher ash content results in a slower solubility, S
Natural graphite elevated tapping and N content is generally low, varying analysis 4
temperature (depending on the storage facility)

Coke: amorphous carbon

Acetylene coke
all iron alloys High C content, slower solubility, low S, N content 5
Granular and pellets
Low sulphur petroleum
all iron alloys High C content, good solubility, low S, N, ash content 1
coke (Needle coke)
grey iron, steel
Medium sulphur
casting and steel High C content, acceptable solubility 2
petroleum coke
production
High sulphur and grey iron and steel High C, S, N content, slower solubility with higher
3
nitrogen petroleum coke production saturation levels

Metallurgical Coke High ash content, requires high melting temperatures

steel production 6
Breeze and a low C saturation of the molten metal

Pellets

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 Type of Field of Solubility
Properties / Advantages / Disadvantages
recarburiser application 1–6
High C content, with an elevated content of volatile
matter, ideally suited for the base iron carburization.
Carbon pellets all iron alloys 4
Also suitable for rotary furnaces. Pellets are available
with different chemical compositions

Anthracite: amorphous carbon

iron alloys with a
Electrically calcined The higher ash content results in a slower solubility, S
high tapping 5
anthracite and N content depends on the storage facility
temperature
iron alloys with a The higher ash content leeds to a slower solubility. S
Gas-calcined anthracite high tapping and N content depends mainly on the geological 5
temperature deposit.
iron alloys with a
Similar to ECA and GCA, but with higher volatile
Dried Anthracite high tapping 5
components
temperature

6. Specifications of good recarburizer and choice of right recarburizer

At present, there are many materials for cast iron recarburizers on the market. In general, coal
quality recarburizers, petroleum coke recarburizers, calcined petroleum cokes, graphitized
petroleum coke recarburizers and artificial graphite can be used as cast iron smelting. Although
these products can be used as recarburizers, we must choose the right recarburizer when we buy
them.
If the quality of the products to be cast is high, it is need to choose artificial graphitized petroleum
coke recarburizer. If the quality of the smelting metal is not high, you can choose a lower cost
recarburizer. For example, in converter smelting, when high carbon steel is used, you can use
petroleum coke with a lot of impurities as a recarburizer. However, the requirements for the
recarburizer for the top-blown converter steelmaking are higher than the carbon of the fixed
furnace recarburizer. The ash, volatiles, sulfur, phosphorus, nitrogen and other impurities are also
required to be high in content, and are required to be dry, clean, and granular. Moderately, it is
necessary to choose a calcined coke recarburizer and a graphitized recarburizer.
Among them, the most used mainstream carbonizers specifications are:

Component Value
Fixed carbon C ≥ 98%
Volatile matter ≤ 1.0%
Sulfur content ≤ 1%
Moisture ≤ 0.5%
Particle size <1-5mm
Different types of recarburizers are used differently. In the process of selecting a recarburizing
agent for steel making, the particle size should be moderate, the particle size is too fine to be easily

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burned, and when it is too coarse to be added, it floats on the surface of the molten steel and is not
easily absorbed by the molten steel. With the development of the market, the quality requirements
of steelmaking refining agents are getting higher and higher, especially the conversion from coal
quality carbonizers to calcined petroleum coke recarburizers, or graphitized petroleum coke
recarburizers.

7. Choice of right recarburizer recarburizer for cast iron with induction

electric furnace and efficient way of using recarburizer
In recent years, more and more factories use the induction electric furnace for cast iron, but usually
only the metal material cannot keep the carbon content in iron, so that's why it need the
recarburizer. For the induction electric furnace, specially the intermediate frequency furnace,
adding the carbon material is important link for smelting.

1. Should choose the carbon additive with low nitrogenn

The usual nitrogen content in cast iron liquid is below 100 ppm. If the nitrogen content exceeds
this concentration (150-200 ppm or higher), it is easy to cause cracks, shrinkage or loose defects
in the casting, and thick-walled castings are more likely to occur. This is caused by an increase in
the amount of recarburizer added when the proportion of scrap steel increases. Coke-based
recarburants, especially bitumen coke, contain large amounts of nitrogen. The graphite carburizer
has a nitrogen mass fraction of 0.1% or less or a very small amount, and the pitch pyrolysis mass
fraction is about 0.6%. If 2% of the recarburizer with a mass fraction of 0.6% nitrogen is added,
this increases the nitrogen content by 120 ppm. A large amount of nitrogen is not only liable to
cause casting defects, but also nitrogen can promote pearlite compaction, ferrite hardening, and
strongly increase strength.

2. Ways to adding the recarburizer

The stirring of molten iron can promote carbon addition. Therefore, the medium frequency
induction electric furnace with weak stirring force is much more difficult to increase carbon
than the power frequency induction electric furnace with strong stirring power. Therefore,
the medium frequency induction electric furnace has the lower carbonization speed and the lower
melting rate of the metal charge.
Even in a power-frequency induction furnace with high stirring power, the carbon-increasing
operation cannot be ignored. This is because, from the schematic diagram of the induction furnace
melting, there is a stirring iron flow separated vertically in the induction furnace, and there is a
dead angle near the furnace wall at the boundary. The graphite cluster which stays on the furnace
wall and adheres cannot be melted into the molten iron without excessive temperature rise and
long-term iron liquid heat preservation. Excessive heating of the molten iron and long-term heat

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preservation will increase the degree of supercooling of the molten iron and increase the tendency
of the cast iron to become white cast iron. In addition, for medium frequency induction furnaces
that generate a strong induced current near the furnace wall, if molten iron is drilled between the
graphite clusters attached to the furnace wall, the drilled metal is melted during the next furnace
smelting, resulting in erosion. And damage the furnace wall. Therefore, in the case where the
proportion of scrap steel is high and the amount of recarburizing agent is added, it is necessary to
pay more attention to the addition of the recarburizing agent.
The addition time of the recarburizer cannot be ignored. If the addition time of the recarburizing
agent is too early, it is easy to adhere to the vicinity of the bottom of the furnace, and the
recarburizing agent adhering to the furnace wall is not easily melted into the molten iron. On the
contrary, if the joining time is too late, the timing of carbon increase will be lost, causing the
smelting and heating time to be slow. This not only delays the time of chemical composition
analysis and adjustment, but also may cause harm due to excessive temperature rise. Therefore,
the recarburizing agent is preferably added little by little during the process of adding the metal
charge.
When using a recarburizer, place the recarburizer in the middle and lower part of the furnace as
much as possible, and add other charge to reduce the overflow of the recarburizer and increase the
contact surface between the recarburizer and the molten iron.
If the furnace is used in a relatively large furnace, it should be added in multiple times, which can
better improve the dissolution rate and increase the absorption rate of the graphitized recarburizer.
At the same time, the recarburizer is placed on the bottom of the furnace, and it can also buffer the
impact on the bottom of the furnace when the iron is added. This also protects the role of the lining.
The recarburizing agent is used in casting, which can greatly increase the amount of scrap steel,
reduce the amount of pig iron or use no pig iron. Therefore, we should use this correctly when
using it to better reduce costs.

8. Choice of right recarburizer based on recarburizer size and capacity of

furnace
Low levels of sulfur, nitrogen, and hydrogen are key to preventing the production of nitrogen holes
in castings. This requires that the nitrogen content of the recharging agent be as low as possible.
The other indicators of recarburizers, such as moisture, ash, and volatiles, the higher the amount
of fixed breakage, so the high fixed carbon content of these harmful ingredients must not be high.
For different smelting methods, furnace types, and sizes of smelting furnaces, it is also important
to select an appropriate particle size of the carbon reductant, which can effectively increase the
absorption rate and absorption rate of the recarburizer by the molten iron and avoid excessively
small particles. Caused by oxidative damage to the breaker. The particle size is preferably:

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 Furnace capacity Recarburizer particle size
100 kg <10 mm
500 kg <15 mm
1.5 tons <20 mm
20 tons <30 mm

The particle size is too fine to be easily burned, and it is too thick to float on the surface of the
molten steel and is not easily absorbed by molten steel. The recarburizer particle size for the
induction furnace is 0.2-6mm, in which the steel and other ferrous metals have a particle size of
1.4-9.5mm, the high carbon steel requires low nitrogen, the particle size is 0.5-5mm, etc. The
concrete need to be based on the specific furnace type smelting work piece. The details of the types
and so on are specifically judged and selected.

9. Use of recarburizer correctly

When using a recarburizer, place the recarburizer in the middle and lower part of the furnace as
much as possible, and add other charge to reduce the overflow of the recarburizer and increase the
contact surface between the recarburizer and the molten iron to improve carbon efficiency.
If the furnace is used in a relatively large furnace, it should be added in multiple times, which can
better improve the dissolution rate and increase the absorption rate of the graphitized recarburizer.
At the same time, the recarburizer is placed on the bottom of the furnace, and it can also buffer the
impact on the bottom of the furnace when the iron is added. This also protects the role of the lining.
In the early stage, it is added simultaneously with the charge, and the middle stage charge has been
partially melted, and the molten iron can be added in the late stage of melting. However, do not
add more than 0.2% later to avoid coarse graphite. The use of recarburizers must use graphite
recarburizers of good quality and low nitrogen content.
If the iron contains low Ti, it is impossible to neutralize a large amount of nitrogen, and at this
time, a large amount of pores are generated due to the N2 removal. A good recarburizer containing
graphite carbon should be between 95% and 98%, and the S content should be below 0.5%. N.
Content of 500~4000ppm is a poor quality recarburizer.
The recarburizing agent is used in casting, which can greatly increase the amount of scrap steel,
reduce the amount of pig iron or use no pig iron. Therefore, we should use this correctly when
using it to better reduce costs.

10. The attention need to pay in process of recarburizer and scrap steel
Graphitized petroleum coke recarburizers are widely used in steelmaking and casting. Due to the
impact of the market, many manufacturers are looking for ways to increase production efficiency

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while saving resources. Therefore, the scrap + recarburizer process is launched in many steel
casting manufacturers.
No matter what method has its advantages and disadvantages, but the disadvantage of this method
is that the nitrogen content of the waste is much higher than that of cast iron, so the induction
furnace melts the cast iron, we must pay attention to the nitrogen level. This is the only way to
solve this way should pay attention to the nitrogen content of the recarburizer.
The recarburizer is characterized by a soft, elastic texture that can be traced on paper.

11. Use of silicon carbide and recarburizer in cast iron smelting

With the widespread promotion of electric furnace smelting, there are two kinds of non-metallic
materials which are increasing in the application of cast iron smelting including
a) Silicon carbide
b) Recarburizer

In order to improve the metallurgical quality of electric furnace smelting, reduce the heritability
of pig iron and improve the mechanical properties of castings, the application of non-metallic
materials such as silicon carbide and recarburizer has become an inevitable trend, especially when
electric furnace smelting produces high quality cast iron parts.
At present, the silicon carbide products in the domestic market are black and green, their purity is
different, and the price is different. Different companies can choose different silicon carbide
products according to their own conditions and conditions. The microstructure and properties of
cast iron depend to a large extent on the microstructure and quality of the raw materials. Low grade
silicon carbide (about 85% SiC) is an excellent deoxidizer, which speeds up steelmaking and
facilitates the control of chemical composition. Improve the quality of steel.
Silicon carbide can be used as a deoxidizer for steel making and a modifier for cast iron structures.
Silicon carbide deoxidizer is a new type of strong composite deoxidizer, which replaces the
traditional silicon powder carbon powder for deoxidation. Compared with the original process, the
physical and chemical properties are more stable, the deoxidation effect is better, the deoxidation
time is shortened, energy is saved, and the energy is improved. Steelmaking efficiency, improving
the quality of steel, reducing the consumption of raw and auxiliary materials, reducing
environmental pollution, improving working conditions, and improving the comprehensive
economic benefits of electric furnaces are of great value.
Due to the genetic influence of graphite in pig iron, a large amount of scrap steel and recarburizer
have to be used for electric furnace melting. The use of recarburizers is very important, especially
for cylinders and cylinder head castings with high requirements for compactness. It is necessary
to use high temperature graphitized recarburizer. If there is no carbonization agent that has been
graphitized by high temperature, it has a large amount of impurities, a large amount of ash, and it
takes a long time to diffuse into the molten iron.

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If the smelting time is short, the composition of the upper and lower irons in the electric furnace
is not uniform, and the casting is likely to cause shrinkage defects after casting.
In short, the use of two non-metallic materials, such as silicon carbide and recarburizer, on cast
iron has its advantages and disadvantages. It must be carefully selected and used reasonably to
achieve the desired results.
In addition, the high-temperature-treated recarburizer has a high nitrogen content, and the
nitrogen-containing scrap is increased to increase the nitrogen content in the molten iron. When a
certain content is reached, crack-like pore defects are formed in the casting.

12. How to improve the absorption rate of graphitized petroleum coke in

furnace
In the middle frequency furnace smelting, the amount of pig iron charge should be reduced as
much as possible, and the recarburizer should be used to ensure high carbon and relatively increase
the amount of scrap. In order to further improve the application of graphitized recarburizer in the
intermediate frequency furnace and improve the absorption rate, we should also understand some
knowledge of the first pass.
The shape of the graphite is better reflected on the casting, which is beneficial to improve the
mechanical properties, reduce the tendency of shrinkage, and improve the processing performance.
1. When selecting a recarburizer, it is better to choose a carbonaceous agent with moderate
particle size and high density, preferably a graphitized petroleum coke recarburizer.
Because the carbonization agent is denser and the larger the particle size, the more difficult
it is to absorb. Compared with the power frequency furnace, the intermediate frequency
furnace heats up too fast, and the absorption rate of the petroleum coke recarburizer in the
intermediate frequency furnace is lower, in order to achieve the recarburizer. Higher
absorption rate, avoiding long-term high temperature oxidation of the recarburizer, the
power in the early stage should be small enough to prolong the heating time of the
graphitized recarburizer to increase the absorption rate.

2. Further increase the efficiency by mechanical agitation and manual stirring when
necessary. Due to the poor mixing ability of the intermediate frequency furnace, it should
also assist the appropriate manual mixing. For example, the use of transfer bag pouring
iron to promote the dissolution and diffusion of the recarburizer enhances the absorption
rate. The specific gravity of the recarburizer is small, and manual agitation can reduce the
recarburizer floating on the surface. When it is burnt, the stirring can also reduce the
carbonation holding time and shorten the production cycle. However, if the stirring time is
too long, the recarburizer will be burned seriously, so the proper feeding process and
melting power also play an important role in the absorption of the recarburizer.

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 3. A reasonable method of joining, cannot blindly join in one time. In order to avoid slow
smelting and heating time, scrap steel and graphite recarburizer are added in batches during
the batching process. The melting time of each batch is about 15 minutes. In the early stage
of the chemical, lower power is used to avoid excessive temperature. After burning, it is
expected to heat up quickly after the molten iron paste. For example, a total of 100KG of
recarburizer should be added in a way of 50KG+30KG+20KG to avoid the large-scale
addition of the recarburizer to the surface of the molten iron. It cannot be effectively
combined with the molten iron and the temperature is too high to cause burning. The
damage is serious, and the amount of the last addition should be relatively small, avoiding
the addition of a recarburizing agent to the molten iron in large quantities, resulting in
incomplete absorption of graphite recarburizer in the molten iron and production delay.

Steelmaking basically uses coal-based recarburizers. Although the content of fixed carbon is low
and sulfur is high, the melting point of coal-based recarburizer is high, the temperature of cast steel
is high, and the absorption rate of coal is low. However, the burning loss is small, and the effect is
not worse than that of graphitization.
In summary, the method of adding the charge is preferably the addition of carbon to the ingredients,
and the graphitized recarburizer and the scrap are added in batches at the same time, and the last
addition is increased. The amount of carbon should be as small as possible.

13. Summary:
1. The recarburizer is a material used to increase the carbon content in molten metal.
Recarburizer is needed to add in the furnace or the ladle depending on sulfur or gas
requirements. Some generally used recarburizers are:

a) Calcined Pet Coke: high fixed carbon content. Sulfur range from 0.5 – 2%. Used
when sulfur and gas content is not critical.
b) Synthetic Graphite: high fixed carbon content, low sulfur and gas levels. Used when
sulfur (< 0.05%) and gas levels (< 100 ppm) need to be low.
c) Anthracite Coal: low cost but high ash level. Not desirable as a Recarburizer.
d) Metallurgical Coke: low cost but high ash level. Not desirable as a Recarburizer.

2. A good recarburizer containing graphite carbon should be between 95% and 98%, and the
S content should be below 0.5% volatile parts (<1%) and should not contain more than
0.9% of moisture.
3. If the iron contains Nitrogen, N > 0.012%, there is a possibility of nitrogen hole defects in
the casting.
4. For 2 ton furnace the recarburizer particle size should be <20 mm.
5. The recarburizer particle size for the induction furnace is 0.2-6mm.
6. Agitation of molten metal increases the absorption efficiency of recarburizer.
7. Silicon carbide can be used as recarburizer (about 85% SiC is an excellent deoxidizer).

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14. Case Study:

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