Carbon Raiser
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What is Carbon Raiser?
Carbon raiser, also known as carbon additive or recarburizer, is a material added to molten metal to increase its carbon content. When being used in steelmaking or casting, the fixed carbon of carbon raiser can reach more than 95%. It has been widely used in various industries such as metallurgy, chemical, and power.
Cast iron:Gray cast iron is relatively brittle and not impact-resistant,but its chemical composition is stable,so it resists gluing,and pitting corrosion,and is not easily deformed.Chain sprockets made of this material are generally used in applications with low speed and low power.
Advantages of Carbon Raiser
Adjust carbon content
Carbon raisers can increase the carbon content of metals during the steel smelting or casting process. This is critical for producing steel or castings with specific carbon content requirements to meet the material’s hardness, strength, wear resistance and corrosion resistance requirements.
Improve mechanical properties
By increasing the carbon content, carbon raisers can improve the mechanical properties of metals, such as hardness, tensile strength, yield strength, impact toughness and fatigue strength. These performance improvements help increase product life and reliability.
Promote coagulation and shrinkage
During the casting process, carbon raisers can reduce the solidification temperature and shrinkage rate of metal, helping to reduce casting defects such as shrinkage cavities, cracks and deformation. This helps improve casting quality and yield.
Reduce production costs
The use of carbon raisers can replace some high-carbon raw materials, such as coke or graphite, thereby reducing production costs. In addition, the use of carbon raiser can also reduce energy consumption and exhaust emissions, helping to achieve green production.
Improve production efficiency
Carburizing agents can improve the fluidity and filling properties of metal, making it easier for metal to fill molds and cavities. This helps increase production efficiency and reduce scrap rates.
Expand application scope
By adjusting the carbon content, carbon raisers can produce metal products with different properties and uses, such as high-strength parts, wear-resistant materials, conductive materials, etc. This helps expand the metal's application scope and market competitiveness.
Low Nitrogen Carbon Raiser:By calcining green petroleum coke under 2400 C to decrease the sulphur content to 0.05%(500ppm),Nitrogen content to 0.02%(200ppm),and increase the permeability of carbon particles.meanwhile,the speed and absorption rate of carburant agent melting process also been improved in molten steel.
Calcined Petroleum Coke:Calcined Petroleum Coke is used low sulphur petroleum coke as raw materials,by putting them into calcining furnace and under 1300 degrees of high temperature calcination. The moisture and volatile matter and other impurities will be moved off after some physiological reaction.
Calcined petroleum coke is black or dark gray solid, with a metallic luster and porous.
Graphite Petroleum Coke:Graphite Petroleum Coke is used calcined petroleum coke as raw materials.,by putting them into graphitization furnace,The moisture and volatile matter and other impurities will be moved off after some physiological reaction.sometimes it’s been called artificial graphite.
Graphite is used widely in many industry, such as carburetant in metallurgy, casting and precision casting area.making high tempure crucible for smelting.
Artificial graphite:The best quality of carbon raiser is artificial graphite,
The main raw materials of making artificial graphite is superior calcined petroleum coke, adding pitch coke as adhesive together with little other accessories, when all type of raw materials have been matched well, then press them into form and treat under 2500-3000 degree temperature with non oxidizing atmosphere, the Volatile Matter and other impurities content will sharply decreased.
Due to the hign price of artificial graphite products, casting plant commonly used artificial graphite are mostly graphite electrode manufacturing chip, graphite electrode scrap pieces and recycling material, to reduce the production cost.
Coke and Anthracite Coal carbon raiser:During Electric arc furnace steelmaking process,charging coke or anthracite coal as recarburizer, Due to it’s hight ash content and volatile matter, it’s rarely used as carburant agent,
Natural Graphite:Natural graphite can be divided into two categories, flake graphite and microcrystalline graphite, Microcrystalline graphite with high ash content, generally do not do use as iron carburetant，There are many varieties of flake graphite:High carbon flake graphite using chemical method of extraction, or heated to a high temperature fpr oxide decomposition, volatilization, Due to low productivity and high price,it’s rarely been used as carburizing agent, only middle content of graphite can been used as carbon addtive, but also using amount is small.
Application of Carbon Raiser
Steel production
Carbon raisers are mainly used in steel smelting to increase the carbon content of molten iron to improve the hardness and strength of steel. It also improves the mechanical properties and workability of steel.
Industrial fields such as aviation and automobiles
In these fields, carbon raisers are used to manufacture high-strength parts and wear-resistant materials. It can not only increase the hardness and strength of the material, but also improve the processing performance and surface quality of the material.
Foundry industry
During the casting process, carbon raisers can increase the hardness and strength of castings, improve their mechanical properties, and also promote solidification and shrinkage of castings. In addition, carbon raisers can also reduce metal surface tension and viscosity, which is beneficial to the smooth progress of the casting process.
Chemical industry
In the chemical industry, carbon raisers are often used in the manufacture of carbon black, graphite, silicon carbide and other materials to increase the carbon content and hardness of the materials, and enhance the mechanical strength and electrical conductivity of the materials.
Composition of Carbon Raisers
Carbon raisers are primarily composed of two essential materials: petroleum coke and coal tar pitch. Let's explore these components in detail:
Petroleum Coke
Petroleum coke, a byproduct of the oil refining process, serves as a primary ingredient in carbon raisers. It is a carbon-rich material obtained from the thermal decomposition of heavy crude oil residues. The high carbon content and low ash and sulfur levels make petroleum coke an ideal choice for achieving the desired carbon content in steel production. Its availability and consistent quality make it a preferred material in various industries.
Coal Tar Pitch
Coal tar pitch, derived from the distillation of coal tar, acts as a binding agent in carbon raisers. It provides the necessary cohesion and strength to the carbon particles, enabling them to withstand the rigorous conditions of steelmaking processes. Coal tar pitch also aids in controlling the porosity and permeability of the carbon raiser, ensuring efficient carbon absorption during steel production.
Combining the Materials
To create carbon raisers, petroleum coke and coal tar pitch undergo a meticulous blending process. The precise proportions of these materials are carefully determined based on the desired carbon content and specific requirements of the end application. The blending process ensures homogeneity and consistency, resulting in carbon raisers that meet the stringent quality standards demanded by the industry.
Using Method of Carbon Raiser
Furnace input method
Carbon raiser mostly used in Induction Furnace,but the specific usage is not always same according to the technological requirement.
●When carbon raiser used in Medium Frequency Furnace,it should be added into middle and lower part of furnace according to ratio or carbon demand together with other charging materials, recovery rate can reach more than 95%
●If carbon content is insufficient to adjust carbon in molten iron,first clean out slag and add carbon additive,dissolving and absorbing carbon by raising temperature of molten iron,electromagnetic stirring or artificial stirring. Recovery rate can reach about 90%,if adopting low-temperature carbonization process,which means only a part of burden have been melt, under such low-temperature of liquid iron,adding all carburizing agent at once, together with some solid charge to press them into liquid iron and avoid from exposed into surface. Carbon content of liquid iron can increase 1.0% by this method.
Carburet outside the furnace
●Spraying Graphite Powder in package
When choosing graphite powder as carbon raiser, blowing amount would be 40kg/t, and the carbon content of liquid iron should increase from 2% to 3%,meanwhile, the carbon use ratio decreased with the increasing of the iron liquid carbon content,the temperature of liquid iron is 1600 C before carbonization, after decreased to 1299 C. Generally using nitrogen gas as a carrier when spray graphite powder to increase carbon content, But under the condition of industrial production, it is more convenient to use compressed air, also the chemical reaction heat occured during oxygen combustion in compressed air can partially compensate part of cooling, and the reducing atmosphere conductive of CO can surely improve carburization result.
●Using carbon raiser during iron come out process
Put Graphte Powder with size 100-200 mesh into package, or flow into the iron tank,Efficient stirring after the iron liquid come out, as far as possible to make the solution of carbon absorption, carbon recovery rate would be about 50%.
What Are the Factors Affecting the Absorption Rate of Carbon Raiser?
The particle size of carbon raiser
If the size of Carbon Raiser are different, the dissolution-diffusion rate and oxidation loss rate are also different, and the absorption rate of Carbon Raiser depends on the comprehensive effect of dissolution-diffusion rate and oxidation loss rate of carburizer. Therefore, in general, if the Carbon Raiser particles size are smaller, the dissolution rate is faster, and the loss rate is larger. If Carbon Raiser particle size are larger,will have a lower dissolution rate and smaller oxidation loss rate.
The amount of carbon raiser have been added
The added quantity of Carbon Raiser is one of the factors affecting the absorption rate of carburization. At a certain temperature and the same chemical composition, the saturated concentration of carbon in molten iron is constant. At a certain saturation, the more Carbon Raiser are added, the longer time needed for the dissolution and diffusion, corresponding will have greater loss and lower the absorptivity.
Temperature
From the point of view of kinetics and thermodynamics, the oxidation of molten ironl is related to the equilibrium temperature of C-Si-O system. The equilibrium temperature varies with the target Carbon and Silicon content. When the molten iron is higher than the equilibrium temperature, carbon oxidation first occurs, and Carbon and Oxygen form CO and CO2, thus the carbon oxidation loss in molten iron increases. When the carburization temperature is above the equilibrium temperature, the absorption rate of the Carbon Raiser decreases, when it's at the equilibrium temperature, the absorption rate of the Carbon Raiser is the highest.
Influence of molten iron stirring
Stirring is beneficial to the dissolution and diffusion of carbon content, and also can reduces the burning loss of the Carbon Raiser which floated on the surface. therefore, before the Carbon Raiser is completely dissolved,the longer the stirring time is; the higher absorptivity is . however, if the stirring time is too long, it not only has a great influence on the service life of the furnace, but also after the Carbon Raiser is dissolved, stirring will aggravate the loss of carbon content in molten iron. Therefore, the proper stirring time of molten iron should ensure the complete dissolution of the Carbon Raiser.
The chemical composition of molten iron
The chemical composition of molten iron will also affect the absorption rate of Carbon Raiser. When the initial carbon content of molten iron is higher, the absorption rate of Carbon Raiser is slower, the absorption amount is smaller, and the burning loss is large. When the initial carbon content of molten iron is low, the situation is just the opposite. Silicon and sulfur in molten iron hinder the absorption of carbon and reduce the absorptivity of Carbon Raiser, while manganese contributes to the absorption of carbon and improves the absorptivity of Carbon Raiser.
Melting process
The operation methods and process steps in the whole melting process have a great influence on the absorptivity of Carbon Raiser. The adding sequence and time of Carbon Raiser will affect the melting and absorption rate too. The weight of carburizer added is different from the proportion of electric furnace melting, which will also affect its absorption rate.
Size of electric furnace
For electric furnaces below 0.5T, when the amount of steel scrap exceeds 50, a large amount of Carbon Raiser need to be added. If the furnace is small, the absorptivity of Carbon Raiser will also be affected. With the increase of smelting time, when steel scrap is used in electric furnace below 0.5T, the selection of steel briquette or pressing cake with high strength can not only improve the smelting speed, but also improve the absorption rate of Carbon Raiser.
The quality of the Carbon Raiser
The quality of the Carbon Raiser is the subjective factor affecting the absorptivity,if the Carbon Raiser has low fixed carbon content and many impurities, which leads to slow melting. This kind of Carbon Raiser is easy to mix with the slag in molten iron, which affects the melting time, and the slag is removed out of the furnace together with the slag. In this case, the Carbon Raiser must be replaced.
The adding method of filling carbon raiser
The wrong adding method of rearburizer are also the reasons for the low absorption rate result ,especially when molten iron melts more than 70% of the volume of electric furnace, and a large quantity of Carbon Raiser is added, the scrap rate will exceed 35%. Therefore, casting strictly accordance with the batching process can not only improve the casting quality, but also fully absorbration of Carbon Raiser
Carbon Raiser Election Principles in Nodular Cast Iron Should Pay Attention To
In the production of nodular cast iron, also known as Ductil Iron, the use of a high-quality carbon raiser is critical to achieving the desired properties of the final product. One of the commonly used types of carbon raiser is graphite petroleum coke (GPC), which is made from petroleum coke through a process that involves heating at high temperatures. When selecting a carbon raiser for nodular cast iron production, several factors must be taken into consideration. The most crucial of these factors are fixed carbon content, sulfur content, ash content, volatile matter, nitrogen content, and hydrogen content.
Fixed carbon content is the percentage of carbon that remains in the GPC after all volatile matter and ash have been burned off. The higher the fixed carbon content, the better the carbon raiser will be at increasing the carbon content of the molten iron. It is recommended that GPC with fixed carbon content of at least 98% should be used for nodular cast iron production.
Sulfur is a common impurity in GPC, and its presence can have adverse effects on the final properties of the nodular cast iron. Therefore, it is important to select GPC with a low sulfur content, typically less than 1%.
Ash content is the amount of non-combustible matter present in GPC. A high ash content can create slag in the furnace, leading to increased costs and decreased efficiency. This is why it is recommended to use GPC with ash content of less than 0.5%.
Volatile matter includes any gases or liquids that are released when the GPC is heated. Higher volatile matter content suggests that the GPC can release more gases, which can create porosity in the final product. Thus, GPC with volatile matter content of less than 1.5% should be used.
Nitrogen content is another impurity in GPC that should be kept lower as it can affect the mechanical properties of the nodular cast iron. GPC with less than 0.3% nitrogen content is ideal for nodular cast iron production.
Finally, hydrogen content is another factor that must be considered when choosing a carbon raiser for nodular cast iron production. Higher hydrogen levels can lead to increased brittleness and reduced ductility. GPC with hydrogen content of less than 0.5% is preferred.
Precautions for Storing Carbon Raiser
When storing carbon raiser, there are the following precautions:
Sealing
Carburizing agent must be stored in a sealed container to ensure that it is not affected by moist air. Wet carbon raiser may cause the carbon content to decrease, affecting its performance.
Moisture-proof and moisture-proof
In addition to sealing, the place where the carburizing agent is stored should be away from damp and humid environments, such as basements or places near water sources. carbon raiser should be stored in a dry, clean place.
Avoid high temperatures
High temperatures may cause the performance of the carbon raiser to change, so avoid storing it in direct sunlight or in places where temperatures are too high. The ideal storage temperature should be room temperature or slightly cooler.
Fire safety
Carbon raiser is a flammable substance, so it should be stored away from fire sources and flammable items to ensure fire safety.
Avoid impurities
The place where the carbon raiser is stored should be free of impurities, dust or other contaminants to ensure the purity of the carbon raiser.
Turn and check regularly
Long-term storage may cause the carbon raiser to clump or become damp, so the condition of the carbon raiser should be turned and checked regularly to ensure it remains dry and loose.
Avoid prolonged storage
Although carbon raisers have a long shelf life, prolonged storage may result in reduced performance. Therefore, carburizing agents should be used within a reasonable period of time and long-term storage should be avoided.
Certifications
Anyang Jinyuan Supply Chain Management co., Ltd was established in 2021s. It covers an area of 30,000 square meters, with registered capital of 1,638,880 dollars, liquid capital of 6million dollars and annual sales of 16 million dollars. We are capable of researching and developing new products independently. For the past years, we have produced many new and special products for clients of steel mills and foundry industries, which satisfy our clients and help us enjoy good comments and higher praise.
Ultimate FAQ Guide to Ferro Silicon
Q: What is a carbon raiser?
Q: What is the use of carbon additive?
Carbon raiser, also known as carbon additive or recarburizer. It is usually used in converter smelting or high-carbon steel smelting. The carbon additive used in the top-blown converter steelmaking requires high fixed carbon content, low content of impurities such as ash, volatile, moisture, sulfur, and phosphorus.
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