Reclamation Of Induction Furnace Slag By Separation Of Metal And Slag Using Pulverizing System 376z6p
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IJSTE - International Journal of Science Technology & Engineering | Volume 1 | Issue 11 | May 2015 ISSN (online): 2349-784X
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System Mrunal V. Deshmukh PG Student Department of Production Engineering Government College of Engineering, Amravati [M.S.] India
Dr. A. G. Matani Associate Professor Department of Production Engineering Government College of Engineering, Amravati [M.S.] India
Abstract In the manufacturing sector, metal casting industry is one of the essential, key and most imperative commercial enterprises. In the present worldwide situation of subsidence and high intensity among the foundry business, waste istration has a urgent part to play in deciding the edge of one over the other and the business overall. In procedure of cast iron and malleable iron generation, auxiliary crude material and modern squanders are shaped. The most inexhaustible waste beginning in the process is prompting heater slag. Slag are mixes of oxides of metal & non metallic components which shape concoction mixes and arrangements with one another furthermore contain little volume of metals, sulfides of metal and gasses. This slag is arranged off the manufacturing plant floor because of which land sullying happens which diminish ripeness of soil. As the Induction heater slag contain around 10-15% metal, the greater part of commercial ventures like to disregard this valuable metal. In the present examination an endeavor has been made to create system to concentrate metal from impelling heater slag of ferrous foundry at Jadhao Steel and Alloys. Keywords: Electric induction furnace, ferrous foundry, Induction furnace slag, Metal ________________________________________________________________________________________________________
I. INTRODUCTION India is the world's second biggest maker of castings furthermore one of the main 10 as far as normal creation every plant. Ferrous foundries create a lot of waste. The Indian foundry creates around 6 million ton of castings every year. The slag delivered every year is around 1.7 million, it is evaluated around 5000 foundries are working all over India. All foundries produce castings by emptying liquid metal into moulds, commonly comprising of centre and trim sands. When the throwing has cooled and solidified, it is divided from the mould and centre materials in the shakeout process. The castings are cleaned, assessed, and after that dispatched for conveyance. Amid the cast iron generation substantial measure of waste is produced which is dangerous to nature.
II. OBJECTIVES 1) 2) 3) 4) 5)
To Study existing arrangement of slag use at Jadhao Steel & Alloys. Collect mechanical information for slag use in steel commercial enterprises. To different metal from slag of affectation heater to expand the profitability. Analysis of metal contain in slag to lessening expense require for crude material. Estimate expense of metal to overcome misfortunes.
III. METHODOLOGY A. Electric Induction Furnace: In Jadhao steels & compounds electric actuation heater is utilized for cast iron/bendable iron generation. The electric instigation heater is a sort of liquefying heater that uses electric streams to soften metal. Incitement heaters are most suitable for softening and alloying a wide assortment of metals with least soften misfortunes. An electric incitement heater requires an electric curl to deliver the charge. This warming loop is at last supplanted. The pot in which the metal is set is made of stronger materials that can oppose the warmth, and the electric loop itself cooled by a water framework so it doesn't overheat or melt. The upside of the instigation heater is a vitality effective, clean and well-controllable liquefying procedure contrasted with most different method for metal softening. Foundries utilize this kind of heater and now additionally more iron foundries are supplanting vaults with instigation heaters to soften cast iron, as the previous discharge loads of dust and different poisons. All rights reserved by www.ijste.org
184
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System (IJSTE/ Volume 1 / Issue 11 / 029)
Capacity : 500kg Power : 250kw Voltage : 1600-1700v
B. Slag: Amid the operation of electric affectation liquefying heaters, non metallic are created from the different sources, for example, scrap, soil of runner & riser and so forth. Contingent upon the particular procedure being utilized and the sort of iron or steel being liquefied the arrangement of slag will differ. The piece of heater & scoop slag is frequently exceptionally complex. The slag that frame in electrical heater dissolving are the aftereffects of complex responses between silica, iron oxide from steel scrap, other oxidation by items from liquefying, and responses with stubborn linings. The subsequent slag will comprises of complex fluid stage. Slag contain Al2O3 , MgO, SiO2, Fe2O3, CaO & MnO. No. of heat 1 12 per day 312 per month 3744 per year
Table - 1 Production of Slag Weight of CI (kg) Slag produced (kg) 650 12.5 7800 144.6 16900 3133 202800 37596
Induction furnace slag contain metal due to 1) Smelting i.e process in which slag forms a layer above molten metal so that some particles in molten metal stuck to the slag. 2) Breakage of pouring ladle due to use of same ladle again and again. 3) Human error at the time of pouring molten metal from furnace to ladle.
Fig. 1: Electric induction furnace
Fig. 2: Induction furnace slag
C. Process of Crushing and Separation using Pulverizer: 1) Slag of induction furnace is crushed in pulverizer. These pulverizer is generally used to make powder of hardened sand mould. 2) Crushing is done by means of hammer mounted on roller. 3) Metal is separated by use of plate type magnetic separator. Used for lifting & handling of ferromagnetic particles. 4) Strong magnetic field to lift large quantity particles. Particles are detached by separating lower plate from upper magnetic body.
Fig. 3: Crusher
Fig. 4: Crushed slag
All rights reserved by www.ijste.org
185
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System (IJSTE/ Volume 1 / Issue 11 / 029)
Fig. 5: Plate type Magnetic Separator
IV. RESULTS AND DISCUSSION Table - 2 Amount of metal contain in slag Sr no.
Slag (kg)
Metal (kg)
1.
10.1
0.7
2. 3. 4.
9.85 8.5 11.9
0.8 0.65 0.75
5.
8.95
0.9
6.
11.35
1.1
7.
12.8
1.25
8.
10.15
0.95
9.
9.25
1.05
10.
8.5
0.9
11.
Other
3.8
Total= 101.35
12.85
It shows metal contain in slag and also shows other metal i.e pure metal in crystal form which is not crushed in crusher and separated from slag by using magnetic separator. A. Cost Analysis: 1) Cost of Metal: % of metal = 12850/101350 *100 =12.67 Annually slag produced = 37.5 ton. Therefore , amount of metal contain in slag annually = 4.75 ton 1kg of metal cost = Rs 30 4.75 ton metal cost = Rs 1,42,500 2) Electricity Cost: Production of slag per day= 144kg Motor= 5hp 5*746= 3.7kw Time= 2.30hr 2.3*3.7= 8.51kwhr Cost per unit= Rs 9.79 8.51*9.79= Rs 83.31 per day Rs. 83.31*26= Rs 2166.06 per month
All rights reserved by www.ijste.org
186
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System (IJSTE/ Volume 1 / Issue 11 / 029)
Rs. 2166.06*12= Rs. 25992.72 per year 3) Manpower Cost: Time required for crushing= 2.3hr Time required for separation= 1hr Wages per 8hr= Rs.150 1hr= Rs. 18.75 3.3hr*18.75= Rs. 61.87 per day 61.87*26= Rs. 1608.7 per month 1608.7*12= Rs.19305 per year. 4) Net Profit: Electricity cost +Manpower cost = Total cost Rs.25992+Rs.19305 = Rs. 45297 Cost of metal – Total cost = Net profit Rs. 1,42,500 – Rs.45,297 = Rs. 97203
V. CONCLUSION From the results obtained it is been observed that the production of induction furnace slag is 37.5 tons/year and metal contain in that slag is 4.75 tons/year which is costing around Rs. 1,42,500. We also calculate electricity and manpower cost for crushing the slag and separation of metal from it and we came to know that net profit is Rs. 97203.We use remaining slag in red clay bricks manufacturing. The benefits of implementing this method at foundry companies were ascertained, these include: 1) Reducing waste through efficient use of energy and raw materials. 2) Enhancing productivity and increasing product yield through greater efficiency. 3) Increasing profitability and quality of products. 4) Reducing the risks of environmental accidents and avoiding regulatory compliance costs leading to insurance saving. 5) Minimize the adverse impact of disposal on the environment.
REFERENCES [1] [2] [3] [4]
Dr . A.G. Matani, Strategies for better waste management in industrial estates, Journal of Industrial Pollution Control, 22(1), pp.67-72, 2006. Dr . A.G. Matani, Controlling industrial air pollution emissions in developing economies, Journal of Industrial Pollution Control, 22(1), pp.83-88. Dr . A.G. Matani, Strategies for better waste management in industries, Journal of Industrial Pollution Control, 3(2), pp. 67-72, 2006. Dr. Ashok G. Matani S. K. Doifode, Effective Industrial Waste Utilization Technologies towards Cleaner Environment, International Journal of Chemical and Physical Sciences , 4(1), pp.536-540, 2015. [5] Baricova, D., Pribulova A. and Demetera , Comparison of possibilities the blast furnace and cupola slag utilization by concrete production, Archives of Foundry Engineering , 10(1) , pp. 15-18, 2010. [6] Joulazadeh M.H. and Joulazadeh, F. (2010), Slag; Value added steel industry byproducts, Archives of metallurgy and materials, 55(1), pp. 1137-1145. [7] Gikunoo, E., Ofosu-Mensah, L., Tofah H. and Bansah, S, Chemical and Mineralogical Characterization of Ghanaian Foundry Slag, Journal of Minerals & Materials Characterization & Engineering, Vol. 11, pp.183-192. [8] Quijorna, N., Coz, A., Andres, A. and Cheeseman, C. (2012), Recycling of Waelz slag and waste foundry sand in red clay bricks, Resources Conservation and Recycling, Vol. 65, pp. 1– 10. [9] Patange, G.S., Khond M.P. and Chaudhari, N.V. (2012),Some Studies And Investigations Of Foundry Wastes For Sustainable Development, International journal of industrial engineering, Vol. 3, pp. 51-57. [10] Bhosale, P.A., Wagh, M.M. and Shinde, N.N. (2013), Study and Measurements of Waste Heat Recovery of Slag in Melting Furnaces in SME’s Foundry Industry, scholarly research journal for interdisciplinary studies, Vol. 1, pp. 1130-1140. [11] Vondracek, J.E., Ferrous Foundry Waste Minimization Options, P04379, pp. 62-82.
All rights reserved by www.ijste.org
187
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System Mrunal V. Deshmukh PG Student Department of Production Engineering Government College of Engineering, Amravati [M.S.] India
Dr. A. G. Matani Associate Professor Department of Production Engineering Government College of Engineering, Amravati [M.S.] India
Abstract In the manufacturing sector, metal casting industry is one of the essential, key and most imperative commercial enterprises. In the present worldwide situation of subsidence and high intensity among the foundry business, waste istration has a urgent part to play in deciding the edge of one over the other and the business overall. In procedure of cast iron and malleable iron generation, auxiliary crude material and modern squanders are shaped. The most inexhaustible waste beginning in the process is prompting heater slag. Slag are mixes of oxides of metal & non metallic components which shape concoction mixes and arrangements with one another furthermore contain little volume of metals, sulfides of metal and gasses. This slag is arranged off the manufacturing plant floor because of which land sullying happens which diminish ripeness of soil. As the Induction heater slag contain around 10-15% metal, the greater part of commercial ventures like to disregard this valuable metal. In the present examination an endeavor has been made to create system to concentrate metal from impelling heater slag of ferrous foundry at Jadhao Steel and Alloys. Keywords: Electric induction furnace, ferrous foundry, Induction furnace slag, Metal ________________________________________________________________________________________________________
I. INTRODUCTION India is the world's second biggest maker of castings furthermore one of the main 10 as far as normal creation every plant. Ferrous foundries create a lot of waste. The Indian foundry creates around 6 million ton of castings every year. The slag delivered every year is around 1.7 million, it is evaluated around 5000 foundries are working all over India. All foundries produce castings by emptying liquid metal into moulds, commonly comprising of centre and trim sands. When the throwing has cooled and solidified, it is divided from the mould and centre materials in the shakeout process. The castings are cleaned, assessed, and after that dispatched for conveyance. Amid the cast iron generation substantial measure of waste is produced which is dangerous to nature.
II. OBJECTIVES 1) 2) 3) 4) 5)
To Study existing arrangement of slag use at Jadhao Steel & Alloys. Collect mechanical information for slag use in steel commercial enterprises. To different metal from slag of affectation heater to expand the profitability. Analysis of metal contain in slag to lessening expense require for crude material. Estimate expense of metal to overcome misfortunes.
III. METHODOLOGY A. Electric Induction Furnace: In Jadhao steels & compounds electric actuation heater is utilized for cast iron/bendable iron generation. The electric instigation heater is a sort of liquefying heater that uses electric streams to soften metal. Incitement heaters are most suitable for softening and alloying a wide assortment of metals with least soften misfortunes. An electric incitement heater requires an electric curl to deliver the charge. This warming loop is at last supplanted. The pot in which the metal is set is made of stronger materials that can oppose the warmth, and the electric loop itself cooled by a water framework so it doesn't overheat or melt. The upside of the instigation heater is a vitality effective, clean and well-controllable liquefying procedure contrasted with most different method for metal softening. Foundries utilize this kind of heater and now additionally more iron foundries are supplanting vaults with instigation heaters to soften cast iron, as the previous discharge loads of dust and different poisons. All rights reserved by www.ijste.org
184
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System (IJSTE/ Volume 1 / Issue 11 / 029)
Capacity : 500kg Power : 250kw Voltage : 1600-1700v
B. Slag: Amid the operation of electric affectation liquefying heaters, non metallic are created from the different sources, for example, scrap, soil of runner & riser and so forth. Contingent upon the particular procedure being utilized and the sort of iron or steel being liquefied the arrangement of slag will differ. The piece of heater & scoop slag is frequently exceptionally complex. The slag that frame in electrical heater dissolving are the aftereffects of complex responses between silica, iron oxide from steel scrap, other oxidation by items from liquefying, and responses with stubborn linings. The subsequent slag will comprises of complex fluid stage. Slag contain Al2O3 , MgO, SiO2, Fe2O3, CaO & MnO. No. of heat 1 12 per day 312 per month 3744 per year
Table - 1 Production of Slag Weight of CI (kg) Slag produced (kg) 650 12.5 7800 144.6 16900 3133 202800 37596
Induction furnace slag contain metal due to 1) Smelting i.e process in which slag forms a layer above molten metal so that some particles in molten metal stuck to the slag. 2) Breakage of pouring ladle due to use of same ladle again and again. 3) Human error at the time of pouring molten metal from furnace to ladle.
Fig. 1: Electric induction furnace
Fig. 2: Induction furnace slag
C. Process of Crushing and Separation using Pulverizer: 1) Slag of induction furnace is crushed in pulverizer. These pulverizer is generally used to make powder of hardened sand mould. 2) Crushing is done by means of hammer mounted on roller. 3) Metal is separated by use of plate type magnetic separator. Used for lifting & handling of ferromagnetic particles. 4) Strong magnetic field to lift large quantity particles. Particles are detached by separating lower plate from upper magnetic body.
Fig. 3: Crusher
Fig. 4: Crushed slag
All rights reserved by www.ijste.org
185
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System (IJSTE/ Volume 1 / Issue 11 / 029)
Fig. 5: Plate type Magnetic Separator
IV. RESULTS AND DISCUSSION Table - 2 Amount of metal contain in slag Sr no.
Slag (kg)
Metal (kg)
1.
10.1
0.7
2. 3. 4.
9.85 8.5 11.9
0.8 0.65 0.75
5.
8.95
0.9
6.
11.35
1.1
7.
12.8
1.25
8.
10.15
0.95
9.
9.25
1.05
10.
8.5
0.9
11.
Other
3.8
Total= 101.35
12.85
It shows metal contain in slag and also shows other metal i.e pure metal in crystal form which is not crushed in crusher and separated from slag by using magnetic separator. A. Cost Analysis: 1) Cost of Metal: % of metal = 12850/101350 *100 =12.67 Annually slag produced = 37.5 ton. Therefore , amount of metal contain in slag annually = 4.75 ton 1kg of metal cost = Rs 30 4.75 ton metal cost = Rs 1,42,500 2) Electricity Cost: Production of slag per day= 144kg Motor= 5hp 5*746= 3.7kw Time= 2.30hr 2.3*3.7= 8.51kwhr Cost per unit= Rs 9.79 8.51*9.79= Rs 83.31 per day Rs. 83.31*26= Rs 2166.06 per month
All rights reserved by www.ijste.org
186
Reclamation of Induction Furnace Slag by Separation of Metal and Slag using Pulverizing System (IJSTE/ Volume 1 / Issue 11 / 029)
Rs. 2166.06*12= Rs. 25992.72 per year 3) Manpower Cost: Time required for crushing= 2.3hr Time required for separation= 1hr Wages per 8hr= Rs.150 1hr= Rs. 18.75 3.3hr*18.75= Rs. 61.87 per day 61.87*26= Rs. 1608.7 per month 1608.7*12= Rs.19305 per year. 4) Net Profit: Electricity cost +Manpower cost = Total cost Rs.25992+Rs.19305 = Rs. 45297 Cost of metal – Total cost = Net profit Rs. 1,42,500 – Rs.45,297 = Rs. 97203
V. CONCLUSION From the results obtained it is been observed that the production of induction furnace slag is 37.5 tons/year and metal contain in that slag is 4.75 tons/year which is costing around Rs. 1,42,500. We also calculate electricity and manpower cost for crushing the slag and separation of metal from it and we came to know that net profit is Rs. 97203.We use remaining slag in red clay bricks manufacturing. The benefits of implementing this method at foundry companies were ascertained, these include: 1) Reducing waste through efficient use of energy and raw materials. 2) Enhancing productivity and increasing product yield through greater efficiency. 3) Increasing profitability and quality of products. 4) Reducing the risks of environmental accidents and avoiding regulatory compliance costs leading to insurance saving. 5) Minimize the adverse impact of disposal on the environment.
REFERENCES [1] [2] [3] [4]
Dr . A.G. Matani, Strategies for better waste management in industrial estates, Journal of Industrial Pollution Control, 22(1), pp.67-72, 2006. Dr . A.G. Matani, Controlling industrial air pollution emissions in developing economies, Journal of Industrial Pollution Control, 22(1), pp.83-88. Dr . A.G. Matani, Strategies for better waste management in industries, Journal of Industrial Pollution Control, 3(2), pp. 67-72, 2006. Dr. Ashok G. Matani S. K. Doifode, Effective Industrial Waste Utilization Technologies towards Cleaner Environment, International Journal of Chemical and Physical Sciences , 4(1), pp.536-540, 2015. [5] Baricova, D., Pribulova A. and Demetera , Comparison of possibilities the blast furnace and cupola slag utilization by concrete production, Archives of Foundry Engineering , 10(1) , pp. 15-18, 2010. [6] Joulazadeh M.H. and Joulazadeh, F. (2010), Slag; Value added steel industry byproducts, Archives of metallurgy and materials, 55(1), pp. 1137-1145. [7] Gikunoo, E., Ofosu-Mensah, L., Tofah H. and Bansah, S, Chemical and Mineralogical Characterization of Ghanaian Foundry Slag, Journal of Minerals & Materials Characterization & Engineering, Vol. 11, pp.183-192. [8] Quijorna, N., Coz, A., Andres, A. and Cheeseman, C. (2012), Recycling of Waelz slag and waste foundry sand in red clay bricks, Resources Conservation and Recycling, Vol. 65, pp. 1– 10. [9] Patange, G.S., Khond M.P. and Chaudhari, N.V. (2012),Some Studies And Investigations Of Foundry Wastes For Sustainable Development, International journal of industrial engineering, Vol. 3, pp. 51-57. [10] Bhosale, P.A., Wagh, M.M. and Shinde, N.N. (2013), Study and Measurements of Waste Heat Recovery of Slag in Melting Furnaces in SME’s Foundry Industry, scholarly research journal for interdisciplinary studies, Vol. 1, pp. 1130-1140. [11] Vondracek, J.E., Ferrous Foundry Waste Minimization Options, P04379, pp. 62-82.
All rights reserved by www.ijste.org
187
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