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Kaldo converter

January 06, 2023

A Kaldo converter (using the Kaldo process or Stora-Kaldo process) is a rotary vessel oxygen based metal refining method. Originally applied to the refining of iron into steel, with most installations in the 1960s, the process is (2014) used primarily to refine non ferrous metals, typically copper. In that field, it is often named TBRC, or Top Blown Rotary Converter.

History and description

Steel production

 
Evolution of chemical composition and temperature of the liquid steel, during the blowing in a Kaldo converter. The iron content is linked with the slag composition, the others elements are taken in the metal.

The name "Kaldo" is derived from Prof. Bo Kalling, and from the Domnarvets Jernverk (Stora Kopparbergs Bergslag subsidiary) both key in the development of the process.[1] Research into the use of a stirring to promote mixing, and therefore rate of conversion was investigated from the 1940s, and investigations into the use of oxygen began c.1948. The feedstock at the Domnarvet works had a phosphorus content of 1.8-2.0% and so the process was developed with one aim being dephosphorisation. The first production unit was installed in 1954 at Domnarvet Jernverk.[1]

The converter was a top blow oxygen converter, similar to Linz-Donawitz type, using a cylindrical vessel; the vessel was tilted whilst conversion took place, with typical rotation speeds of around 30 revolutions per minute; the oxygen was injected via a lance, with slag forming materials added separately.[2]

Kaldo converters were relatively common in the 1960s in the United Kingdom, during the transition from predominately open hearth process steelmaking to oxygen based steelmaking techniques. Converters were installed at Consett steelworks, Park Gate, Rotherham, Shelton works, Stoke-on-Trent;[3] and Stanton Iron Works.[4] Before the advent of the basic-LD process the Kaldo method was a preferred one in the UK for converting high phosphorus iron.[5] The first unit in the UK was at Park Gate Works, Rotherham.[6]

In the USA the process was installed at the Sharon Steel Corporation (c.1962).[7][8] A plant in Japan was installed for Sanyo Special Steel Co. (Himejii) in c.1965.[9] A combined type of converter (LD-Kaldo), using elements of the Linz-Donawitz and Kaldo processes was installed 1965 in Belgium at Cockerill-Ougrée-Providence's plant in Marchienne-au-Pont as a multicompany research venture.[10][11] In France, one Kaldo furnace was also installed (one 160t unit, 1960) at Sollac's Florange steelworks [fr]. It was followed in 1969 by two huge 240t units, the biggest Kaldo converters never built (two times bigger than the previous bigger ones : 1000t rotating at 30 r.p.m. !), at Wendel-Sidelor's (later Usinor-Sacilor) Gandrage-Rombas steelworks [fr] (Lorraine, France); these two converters did not meet expectations and the third additional planned Kaldo unit was not installed, instead two OLP (oxygène-lance-poudre) 240t units were used.[12]

Disadvantages of the process, compared to non-rotating oxygen furnaces (e.g. LD type) were the higher capital cost, more difficult to upscale to higher outputs, and additional complexity (i.e. rotating parts and loading thereof).[13] Advantages included the ability to use a high proportion of scrap metal, and good controllability of final steel specification.[14] At the Park Gate works conversion time was 90 minutes, with up to 45% scrap loading, with a capacity of 75t in a 500t total, 16 feet (4.9 m) diameter converter, with a rotation speed of 40 revs per minute.[6]

Due to high maintenance costs the Kaldo converter did not gain widespread usage in the steel industry, with non-rotating converters being preferred.[15]

Non-ferrous production

Nickel matte was converted by Inco (Canada) in a pilot Kaldo converter in 1959, and Metallo-Chimique (Belgium) developed secondary copper smelting using the Kaldo type converters in the late 1960s.[15] The Kaldo type converted is commonly known as a Top-Blown Rotary Converter (TBRC) in non-ferrous metal smelting terminology.[16]

By the 1970s the Kaldo furnace was in common use for copper and nickel smelting.[17] A Kaldo converter for the smelting of lead was constructed by Boliden in Sweden in 1976.[17]

Kaldo secondary copper units were still in use worldwide at the beginning of the 21st century, but as of 2011 no new units had been commissioned for around 10 years, suggesting that the process had been superseded.[18]

See also

References

  1. ^ a b Allen 1967, p. 138.
  2. ^ Garmonsway, Donald (20 July 1961), "A survey of oxygen steelmaking", New Scientist (244): 153–155
  3. ^ Heal 1974, p. 114.
  4. ^ "New Iron refining plant at Stanton Works", Iron and Steel, 38: 119–121, 1965
  5. ^ Allen 1967, p. 187, 191.
  6. ^ a b "Computer chain of command in a steelworks", New Scientist (399): 83–84, 9 Jul 1964
  7. ^ Iron and Steel Engineer, 41 (1–3): 181, 1964 {{citation}}: Missing or empty |title= (help)
  8. ^ Industry Week, 151: 33, 17 Sep 1962 {{citation}}: Missing or empty |title= (help)
  9. ^ Stahl und Eisen (in German), 85: 233, 1965 {{citation}}: Missing or empty |title= (help)
  10. ^ Symposium on Belgian Science & Industry, 22-25 March 1966, 1966, p. 185
  11. ^ Nilles, P.; Noel, Y. (March 1973), "Affinage des fontes phosphoreuses en une phase avec décrassage en cours de soufflage", Communauté Européenne du charbon et de l'acier (in French)
  12. ^ Freyssenet, M. (1979), La sidérurgie française. 1945-1979. Histoire d'une faillite. Les solutions qui s'affrontent (PDF) (in French), p. 81
  13. ^ Allen 1967, p. 140, 149.
  14. ^ Allen 1967, pp. 140, 202.
  15. ^ a b Morris 1976.
  16. ^ Rosenqvist, Terkel (2004), Principles of Extractive Metallurgy, pp. 346–7
  17. ^ a b Rich, Vincent (1994), The International Lead Trade, p. 50
  18. ^ King, Matthew J.; Sole, Kathryn C.; Davenport, William G. I. (2011), Extractive Metallurgy of Copper, §19.3.2 p.393

Sources

  • Allen, James Albert (1967), Studies in Innovation in the Steel and Chemical Industries, p. 206
  • Heal, David W. (1974), "The Steel Industry in Post War Britain", Industrial Britain, David and Charles
  • Morris, C.W. (1976), "12. The Development of The Kaldo Furnace Smelting Technique and Its Application for Top Blown Rotary Converter (TBRC) Copper Smelting and Refining", Extractive Metallurgy of Copper, vol. 1

External links

 
Wikimedia Commons has media related to Kaldo converters.
  • "Outotec Kaldo (TBRC) technology", www.outotec.com

January 06, 2023
kaldo, converter, using, kaldo, process, stora, kaldo, process, rotary, vessel, oxygen, based, metal, refining, method, originally, applied, refining, iron, into, steel, with, most, installations, 1960s, process, 2014, used, primarily, refine, ferrous, metals,. A Kaldo converter using the Kaldo process or Stora Kaldo process is a rotary vessel oxygen based metal refining method Originally applied to the refining of iron into steel with most installations in the 1960s the process is 2014 used primarily to refine non ferrous metals typically copper In that field it is often named TBRC or Top Blown Rotary Converter Contents 1 History and description 1 1 Steel production 1 2 Non ferrous production 2 See also 3 References 3 1 Sources 4 External linksHistory and description EditSteel production Edit Evolution of chemical composition and temperature of the liquid steel during the blowing in a Kaldo converter The iron content is linked with the slag composition the others elements are taken in the metal The name Kaldo is derived from Prof Bo Kalling and from the Domnarvets Jernverk Stora Kopparbergs Bergslag subsidiary both key in the development of the process 1 Research into the use of a stirring to promote mixing and therefore rate of conversion was investigated from the 1940s and investigations into the use of oxygen began c 1948 The feedstock at the Domnarvet works had a phosphorus content of 1 8 2 0 and so the process was developed with one aim being dephosphorisation The first production unit was installed in 1954 at Domnarvet Jernverk 1 The converter was a top blow oxygen converter similar to Linz Donawitz type using a cylindrical vessel the vessel was tilted whilst conversion took place with typical rotation speeds of around 30 revolutions per minute the oxygen was injected via a lance with slag forming materials added separately 2 Kaldo converters were relatively common in the 1960s in the United Kingdom during the transition from predominately open hearth process steelmaking to oxygen based steelmaking techniques Converters were installed at Consett steelworks Park Gate Rotherham Shelton works Stoke on Trent 3 and Stanton Iron Works 4 Before the advent of the basic LD process the Kaldo method was a preferred one in the UK for converting high phosphorus iron 5 The first unit in the UK was at Park Gate Works Rotherham 6 In the USA the process was installed at the Sharon Steel Corporation c 1962 7 8 A plant in Japan was installed for Sanyo Special Steel Co Himejii in c 1965 9 A combined type of converter LD Kaldo using elements of the Linz Donawitz and Kaldo processes was installed 1965 in Belgium at Cockerill Ougree Providence s plant in Marchienne au Pont as a multicompany research venture 10 11 In France one Kaldo furnace was also installed one 160t unit 1960 at Sollac s Florange steelworks fr It was followed in 1969 by two huge 240t units the biggest Kaldo converters never built two times bigger than the previous bigger ones 1000t rotating at 30 r p m at Wendel Sidelor s later Usinor Sacilor Gandrage Rombas steelworks fr Lorraine France these two converters did not meet expectations and the third additional planned Kaldo unit was not installed instead two OLP oxygene lance poudre 240t units were used 12 Disadvantages of the process compared to non rotating oxygen furnaces e g LD type were the higher capital cost more difficult to upscale to higher outputs and additional complexity i e rotating parts and loading thereof 13 Advantages included the ability to use a high proportion of scrap metal and good controllability of final steel specification 14 At the Park Gate works conversion time was 90 minutes with up to 45 scrap loading with a capacity of 75t in a 500t total 16 feet 4 9 m diameter converter with a rotation speed of 40 revs per minute 6 Due to high maintenance costs the Kaldo converter did not gain widespread usage in the steel industry with non rotating converters being preferred 15 Non ferrous production Edit Nickel matte was converted by Inco Canada in a pilot Kaldo converter in 1959 and Metallo Chimique Belgium developed secondary copper smelting using the Kaldo type converters in the late 1960s 15 The Kaldo type converted is commonly known as a Top Blown Rotary Converter TBRC in non ferrous metal smelting terminology 16 By the 1970s the Kaldo furnace was in common use for copper and nickel smelting 17 A Kaldo converter for the smelting of lead was constructed by Boliden in Sweden in 1976 17 Kaldo secondary copper units were still in use worldwide at the beginning of the 21st century but as of 2011 no new units had been commissioned for around 10 years suggesting that the process had been superseded 18 See also EditAJAX furnaceReferences Edit a b Allen 1967 p 138 Garmonsway Donald 20 July 1961 A survey of oxygen steelmaking New Scientist 244 153 155 Heal 1974 p 114 New Iron refining plant at Stanton Works Iron and Steel 38 119 121 1965 Allen 1967 p 187 191 a b Computer chain of command in a steelworks New Scientist 399 83 84 9 Jul 1964 Iron and Steel Engineer 41 1 3 181 1964 a href Template Citation html title Template Citation citation a Missing or empty title help Industry Week 151 33 17 Sep 1962 a href Template Citation html title Template Citation citation a Missing or empty title help Stahl und Eisen in German 85 233 1965 a href Template Citation html title Template Citation citation a Missing or empty title help Symposium on Belgian Science amp Industry 22 25 March 1966 1966 p 185 Nilles P Noel Y March 1973 Affinage des fontes phosphoreuses en une phase avec decrassage en cours de soufflage Communaute Europeenne du charbon et de l acier in French Freyssenet M 1979 La siderurgie francaise 1945 1979 Histoire d une faillite Les solutions qui s affrontent PDF in French p 81 Allen 1967 p 140 149 Allen 1967 pp 140 202 a b Morris 1976 Rosenqvist Terkel 2004 Principles of Extractive Metallurgy pp 346 7 a b Rich Vincent 1994 The International Lead Trade p 50 King Matthew J Sole Kathryn C Davenport William G I 2011 Extractive Metallurgy of Copper 19 3 2 p 393 Sources Edit Allen James Albert 1967 Studies in Innovation in the Steel and Chemical Industries p 206 Heal David W 1974 The Steel Industry in Post War Britain Industrial Britain David and Charles Morris C W 1976 12 The Development of The Kaldo Furnace Smelting Technique and Its Application for Top Blown Rotary Converter TBRC Copper Smelting and Refining Extractive Metallurgy of Copper vol 1External links Edit Wikimedia Commons has media related to Kaldo converters Outotec Kaldo TBRC technology www outotec com Retrieved from https en wikipedia org w index php title Kaldo converter amp oldid 1091124763, wikipedia, wiki, book, books, library,

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