The SinterCast Process for pressurised pouring furnaces begins by base treating the iron with magnesium. The magnesium addition is effected by 'pure' magnesium additions by wirefeeder or converter to minimise slag build-up in the furnace. The regular addition of fresh Mg-treated base iron into the pouring furnace, combined with a predictable Mg-fade rate, provides a stable platform for CGI production. The Mg-treated iron is ultimately inoculated by injecting inoculant cored-wire into the pouring spout as the iron is being dispensed into the mould.
The control actions are determined based on the result of the SinterCast thermal analysis sample obtained from either the exit spout of the furnace or the pouring basin of a newly-filled mould. The sample timing is chosen to ensure that the thermal analysis result is available on-time to determine the magnesium addition for the next treatment ladle. One Sampling Cup is used for each treatment ladle.
Depending on the result of the thermal analysis, the amount of magnesium added to subsequent base treatments is automatically increased or decreased to concentrate or dilute the magnesium content of the bulk iron already in the furnace. Similarly, the inoculant injection can be increased or decreased to adjust the amount of inoculant added to the pouring spout during the pouring time. Finally, in the event of lengthy line stoppages, or at start-up, an optional wirefeeder can be configured to add Mg-wire directly to the furnace body. This eliminates the potential need for pigging iron and allows direct start-up with in-spec CGI even after the furnace has been down during prolonged line stoppages.