IRON PRODUCTION ADDITIVE

Abstract

An oxidation reduction additive useful in iron production is disclosed. The additive may be produced as an aggregate composed of Silicon carbide, graphite and bentonite which is added to iron during production to reduce oxidation loses, slag generation and increase the yield of iron. The iron casting produced using the disclosed additive has improved properties including increased fluidity, tensile strength and nodularity.

Claims

1. An oxidation reduction additive useful in iron production comprising: a) a portion composed of a silicon carbide material; b) a portion composed of a bentonite material; and, c) a portion composed of a graphite material, the portions mixed together to form an additive for oxidation reduction during iron production.

2. The oxidation reduction additive useful in iron production according to claim 1 wherein the proportion of the graphite to the silicon carbide material is at least 2:1.

3. The oxidation reduction additive useful in iron production according to claim 1 wherein the proportion of the graphite to the silicon carbide material is 2:1.

4. The oxidation reduction additive useful in iron production according to claim 1 wherein the bentonite material is less than 1% weight of the additive.

5. The oxidation reduction additive useful in iron production according to claim 1 wherein the weight percent of silica carbide is 33% and the weight percent of bentonite is 0.25%.

6. The oxidation reduction additive useful in iron production according to claim 1 the weight percent of Silicon carbide is 30%-40%, the weight percent of bentonite is 0.05%-2.5% and the weight percentage of graphite is 60%-70%.

7. The oxidation reduction additive useful in iron production according to claim 1 wherein the additive was added to a charge mix, having a charge mix weight, at a rate of between 0.20-0.30 weight percent of the charge mix weight.

8. The oxidation reduction additive useful in iron production according to claim 1 wherein the additive was added to a charge mix, having a charge mix weight, at a rate of between 0.1-0.40 weight percent of the charge mix weight.

9. The oxidation reduction additive useful in iron production according to claim 1 wherein upon introduction of the additive into the charge mix results in a reduction of a quantity of slag produced.

10. The oxidation reduction additive useful in iron production according to claim 1 wherein the additive was added to a charge mix, having a charge mix weight, at a rate of between 0.1-0.40 weight percent of the charge mix weight and reduced oxidation during iron melt.

11. The oxidation reduction additive useful in iron production according to claim 1 wherein the additive is manufactured from a combination of components selected from the group consisting of silicon, carbon and clay and or combinations therein.

12. The oxidation reduction additive useful in iron production according to claim 1 wherein the additive is manufactured from a combination of components selected from the group consisting of silicon carbide, bentonite, and carbon graphite and or combinations therein.

13. An oxidation reduction additive useful in iron production comprising: a) a portion composed of a silicon carbide material forming a core; b) a binder composed of a bentonite material forming a binder layer affixed to the core; c) an outer layer composed of a graphite material, the outer layer affixed to the binder layer to form an aggregate.

14. The oxidation reduction additive useful in iron production according to claim 13 wherein the proportion of the graphite to the silicon carbide material is 2:1 by weight.

15. The oxidation reduction additive useful in iron production according to claim 13 wherein the bentonite material is less than 1% weight of the additive.

16. The oxidation reduction additive useful in iron production according to claim 13 wherein the weight % of bentonite in the additive is 0.5-3.0%.

17. The oxidation reduction additive useful in iron production according to claim 13 wherein the weight percent of Silicon carbide is 30%-40%, the weight percent of bentonite is 0.05%-2.5% and the weight percentage of graphite is 60%-70%.

18. The oxidative reduction additive useful in iron production according to claim 13 wherein the additive is added to a charge mix, having a charge mix weight, at a rate of between 0.1-0.40 weight percent of the charge mix weight.

19. The oxidation reduction additive useful in iron production according to claim 13 wherein the additive is manufactured from a combination of components selected from the group consisting of silicon, carbon and clay and or combinations therein.

20. The oxidation reduction additive useful in iron production according to claim 1 wherein the additive is manufactured from a combination of components selected from the group consisting of silicon carbide, bentonite, and carbon graphite and or combinations therein.

21. The oxidation reduction additive useful in iron production according to claim 13 wherein upon introduction into the charge mix results in a reduction of a quantity of slag produced during iron production.

Description

DETAILED DESCRIPTION-BRIEF DESCRIPTION OF DRAWINGS

[0027] In order that the advantages of the present disclosure will be readily understood, a more particular description of various illustrative embodiments briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings.

[0028] Understanding that these drawings depict only typical embodiments and are not therefore to be considered limiting of its scope unless otherwise indicated in the following claims, the illustrative embodiments will be described and explained with additional specificity and detail through the use of the accompanying drawings.

[0029] FIG. 1 is a simple diagram of the cast iron production process for use with the additive disclosed.

[0030] FIG. 2A illustrates an image of an illustrative iron casting produced from the process as disclosed at FIG. 1.

[0031] FIG. 2B illustrates an image of another illustrative iron casting produced from the process as disclosed at FIG. 1.

[0032] FIG. 3 is an illustrative view of the additive embodied as an aggregate.

[0033] Table A provides a summary of the laboratory (lab) results including the variables measures and the benefits.

[0034] FIG. 4 is an illustrative graph plotting a comparison of the Slag Generated per Heat.

[0035] Table A summarizes the percent (%) increase in fluidity for heats 2-11 over the baseline labeled as heat 1.

[0036] FIG. 5 is an illustrative plotting Slag Weight for Cold Start heats (1, 3, 5-6, 9, 10-11).

[0037] FIG. 6 is an illustrative plotting of Fluidity across heats 1-11.

[0038] Table B summarizes the percent (%) change of fluidity across heats 1-11.

[0039] FIG. 7 is an illustrative plotting of the fluidity data across heats 1-11.

[0040] FIG. 8 compares the expected fluidity versus the measured fluidity in support of validation of the pilot data produced.

[0041] FIG. 9 is an illustrative plotting of the fluidity data across heats 1-11.

[0042] Table C summarizes the nodule count and nodularity of the iron casting produced for heats 2-11 over the baseline labeled as heat 1.

[0043] FIG. 10 is an illustrative plotting of tensile test results across heats 1-11.

[0044] Table D summarizes the additive formulation used in the iron production process for heats 1-11.

[0045] FIG. 11 is an illustrative plotting for the durability of the various additive blends for heats 1-11.

[0046] Table E itemizes the composition of the base charge mix used in heats 1-11.

[0047] Table F summarizes the background objectives of the study.

[0048] Table G summarizes the background variables of the study.

[0049] Table H summarizes the industrial trial hypotheses.

[0050] FIG. 12A and FIG. 12B are images are qualitatively confirming the slag consistency of heat 1 (1334 grams of slag) versus heat 5 (670 grams of slag).

[0051] FIGS. 13A and 13B are images of partially filled fluidity spirals for heats 3 and 4 (approximately 1350 mm) versus filled fluidity spirals for heats 5, 6, 10 and 11 (1500 mm).

[0052] FIG. 14 is a visual confirmation of the fluidity thin wall study completed during the pilot study.

[0053] Appendix A is incorporated by reference herein for additional supporting evidence for the disclosure of the additive and pilot studies providing evidence of improvements to the cast iron production process and improvements to the cast iron products produced.

[0054] Appendix B is incorporated by reference herein and provides a listing of equipment and properties tested related to iron castings.

[0055] Appendix C is incorporated by reference herein and provides a listing of illustrative iron casting products and ASTM testing methods which this disclosed additive is relevant to.

[0056] Appendix D is an industrial product trial template for describing a trial using at least one embodiment of the additive and or aggregate configured as an additive herein.

TABLE-US-00001 DETAILED DESCRIPTION - TABLE OF ELEMENTS Element Description Element Number Cast Iron Production Process 1 Charge bucket 2 Melting furnace 3 Melting furnace lining 3a Pouring ladle 4 Mold 5 6 Silicon carbide 7 Core 7a Bentonite 8 Binder 8a Carbon graphite 9 Outer layer 9a Additive 10 Aggregate 10a Heat energy (Flame, forced air) 11 Electrical energy 12 Alloying materials (added) 13 Measure iron chemistry 14 Elements too low 15 Slag coagulant (input) 16 Iron returns 17 Steel scrap 18 Pig iron 19 Charge mix - dried and pre-heated 20 Charge mix mass 20a Alloying materials 21 Slag (product of oxidation) 22 Iron casting 30 Iron - molten iron poured into mold 30 Iron casting properties 30a 40 Pilot study 50

DETAILED DESCRIPTION OF INVENTION

[0057] Before the present methods and apparatuses are disclosed and described, it is to be understood that the methods and apparatuses are not limited to specific methods, specific components, or to particular implementations. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments/aspects only and is not intended to be limiting.

[0058] As used in the specification and the appended claims, the singular forms a, an, and the include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from about one particular value, and/or to about another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent about, it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0059] Optional or optionally means that the subsequently described event or circumstance may or may not occur, and that the description includes instances where said event or circumstance occurs and instances where it does not.

[0060] Aspect when referring to a method, apparatus, and/or component thereof does not mean that limitation, functionality, component etc. referred to as an aspect is required, but rather that it is one part of a particular illustrative disclosure and not limiting to the scope of the method, apparatus, and/or component thereof unless so indicated in the following claims.

[0061] Throughout the description and claims of this specification, the word comprise and variations of the word, such as comprising and comprises, means including but not limited to, and is not intended to exclude, for example, other components, integers or steps. Exemplary means an example of and is not intended to convey an indication of a preferred or ideal embodiment. Such as is not used in a restrictive sense, but for explanatory purposes.

[0062] Disclosed are components that can be used to perform the disclosed methods and apparatuses. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these may not be explicitly disclosed, each is specifically contemplated and described herein, for all methods and apparatuses. This applies to all aspects of this application including, but not limited to, steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods.

[0063] The present methods and apparatuses may be understood more readily by reference to the following detailed description of preferred aspects and the examples included therein and to the figures and their previous and following description.

[0064] Before the various embodiments of the present invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that phraseology and terminology used herein with reference to device or element orientation (such as, for example, terms like front, back, up, down, top, bottom, and the like) are only used to simplify description of the present invention, and do not alone indicate or imply that the device or element referred to must have a particular orientation. In addition, terms such as first, second, and third are used herein and in the appended claims for purposes of description and are not intended to indicate or imply relative importance or significance.

[0065] The following detailed description is of the best currently contemplated modes of carrying out illustrative embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appending claims. Various inventive features are described below herein that can each be used independently of one another or in combination with other features.

Illustrative Embodiment of a Process Using an Additive

[0066] FIG. 1 is a simplified diagram of the prior cast iron production process 1 for use with the additive 10 disclosed. (Additive 10 is not PRIOR ART but is intended to be used with PRIOR ART cast iron production process 1) As shown a typical foundry process starts with a charge bucket 2 for collection of the inputs to the process which are some ratio of iron returns 17 (i.e. recycled iron castings), steel scrap 18 and pig iron 19. This combination of inputs are the charge mix 20 which is dried and pre-heated in the charge bucket 2 before delivery to the melting furnace. The additive 10 is typically added to the charge mix 20 as shown in FIG. 1. The charge mix 20 is delivered to the melting furnace 3 to melt the charge mix with either heat energy 11 or electrical energy 12. As shown, alloying materials may be added to the melting furnace 3, subject to the desired properties of the final iron casting 30. After reaching the appropriate operating temperature (or after sufficient time) for the charge mix 20 in the melting furnace 3, with furnace liner 3a, the molten iron 30a is distributed to the pouring ladle 4 for final delivery to the mold 5 to produce the iron casting 30. It is at least one objective of the disclosed additive 10 to improve the iron production process with no other changes, or minimal changes, to the general cast iron production process disclosed at FIG. 1. FIG. 2A illustrates an image of an illustrative iron casting 30 produced from the process as disclosed at FIG. 1. As understood by one of ordinary skill in the art, the iron casting 30 is the product released from the mold after cooling. FIG. 2B illustrates an image of another illustrative iron casting produced from the process as disclosed at FIG. 1. One of ordinary skill will appreciate that other steps, structures and processes may be used as suitable for a particular application to achieve similar functionality without limitation.

Illustrative Embodiment of an Additive

[0067] In at least one embodiment of the additive 10 which has been found to be useful in iron production as disclosed herein, the additive 10 is composed of Silicon carbide 7, bentonite 8 and carbon graphite 9. Silicon carbide 7, is also commonly known as Carborundum, a compound of silicon and carbon. In at least one embodiment, bentonite 8 is a highly absorbent, viscous plastic clay which has use as a binding, sealing, absorbing and or lubricating agent. In at least one embodiment, bentonite 8 is an aluminum phyllosilicate clay composed of montmorillonite with the chemical formula (Ca,Na).sub.0.3(Al,Mg).sub.2Si.sub.4O.sub.10(OH).sub.2.Math.n H.sub.2O. One of ordinary skill will appreciate that other materials, including other versions of bentonite and or other clay type materials, may be used as suitable for a particular application including dirt clay, sodium bentonite, kaolin and or polymer clay, and or combinations therein. The table below lists the proportion, by weight, of each component, in at least one embodiment of the additive as well as the upper and lower ranges of each component in the additive 10. One of ordinary skill will appreciate that other proportions and or ranges may be used as suitable for a particular application.

TABLE-US-00002 TABLE 1 ADDITIVE COMPONENTS Component Percentage by Weight (%) Range Silicon Carbide 33% 30%-40% Bentonite 1% 0.05%-2.5% Carbon graphite 66% 60%-70%

[0068] In at least one embodiment, the oxidation reduction additive useful in iron production the proportion of the graphite to the silicon carbide material is at least 2:1, as suitable for a particular application. In other embodiments, the proportion of carbon graphite material 9 to silicon carbide 7 may be in equal to or in excess of 2:1, as suitable for a particular application. One of ordinary skill will appreciate that the additive 10 is not limited to the combination of silicon carbide 7, bentonite 8 and carbon graphite 9 disclosed and may be composed of other materials which are abundantly available and provide adequate sources of carbon, silicon and binder, as required for a particular application, including use as an oxidation reduction additive 10. Without limitation or restriction, other materials suitable for use as an additive 10 may include silicon, carbon, silicon carbide, carbon graphite, graphene, bentonite, dirt clay, sodium bentonite, kaolin and or polymer clay, and or any other suitable combinations of the aforementioned materials therein.

Illustrative Embodiment of an Additive Aggregate

[0069] FIG. 3 is an illustrative view of the additive 10 formed into an aggregate having the characteristics as shown in FIG. 3 and disclosed herein to form an additive aggregate 10a. The additive aggregate 10a has been found to be useful in iron production and is comprised of a portion composed of a Silicon carbide 7 material forming a core 7a. A binder layer 8a is then affixed to the core 7a. In at least one embodiment, the binder layer 8 is composed of a bentonite material 8. An outer layer 9, composed of a graphite material 9a, is then affixed to the binder layer 8 to form an aggregate additive 10a. One of ordinary skill will appreciate that bentonite 8 is material that is a satisfactory binder. Other materials may be satisfactory, particularly, other clay based materials, with properties to coat and bind with silicon and carbon materials.

TABLE-US-00003 TABLE 2 AGGREGATE ADDITIVE COMPONENTS Component Percentage by Weight (%) Range Silicon Carbide 33% 30%-40% Bentonite 0.25% 0.5%-2.5% Carbon graphite 67% 60%-70%

[0070] At least one embodiment of the aggregate additive 10a was produced by blending bentonite 7 into water to form a slurry to which the Silicon carbide 7 was then added. Carbon graphite 9 was then added to the binder coated Silicon carbide to make the aggregate additive 10a disclosed at FIG. 3. Based on the data of the pilot study 50, the aggregate additive slurry binder outperformed the dry blend and water blend for maintaining the carbon coating on the Silicon Carbide 7. (See discussion herein and Appendix A, pages 6-26)

[0071] In at least one embodiment, the aggregate additive 10a useful in iron production the proportion of the graphite 9 to the Silicon carbide 7 is 2:1. In at least one embodiment, the aggregate additive 10a useful in iron production contains bentonite material 8 which is less than 1% weight of the aggregate additive 10a. In at least one embodiment, the aggregate additive 10a useful in iron production upon introduction to an iron charge mix 20 reduced a quantity of slag produced.

[0072] In another embodiment, the reduction of slag produced was fifty percent (50%). In at least one embodiment, including the aggregate additive 10a in the iron casting process resulted in an iron casting having a fifty percent (50%) increase in fluidity. (See Heats 5, 6, 7, 10 and 11 with Fluidity % increase by 49.69%, 57.23%, 57.23%, 57.23%, and 57.23%, respectively). In at least one embodiment, additive 10 was added to the charge mix 20 at a rate of between 0.28-0.30 weight percent of the charge mix mass 20a.

[0073] One of ordinary skill will appreciate that the additive 10 configured as an aggregate 10a is not limited to the combination of silicon carbide 7, bentonite 8 and carbon graphite 9 disclosed and may be composed of other materials which are abundantly available and provide adequate sources of carbon, silicon and binder, as required for a particular application, including use as an oxidation reduction additive 10a. Without limitation or restriction, other materials suitable for use as an additive 10a may include silicon, carbon, silicon carbide, carbon graphite, graphene, bentonite, dirt clay, sodium bentonite, kaolin and or polymer clay, and or any other suitable combinations of the aforementioned materials therein.

Illustrative Trials and Pilot Studies

[0074] As disclosed and discussed at length in Appendix A, at least one embodiment of the additive disclosed herein was the subject of small-scale pilot studies 50, the results 50a of which support the present disclosure and claims made. (See pages 1-36 of Appendix A, incorporated by reference herein, for further details)

[0075] In the pilot study 50 eleven (11) heats were conducted using a standard charge mix which was foundry ductile iron returns (45%), steel scrap (32%), steel bushlings (10%) and pig iron (10%) as disclosed in Table E. The components of the charge mix 20 were selected to eliminate variability and produce consistent data sets for comparison and analysis purposes. One of ordinary skill will appreciate that use of the additive 10 and aggregate additive 10a with the casting process is not limited to this particular charge mix 20.

[0076] The results 50a of the pilot study indicate at least one embodiment of the additive measurably reduced slag weight and improved slag consistency. One of ordinary skill will appreciate that reduced slag weight decreases disposal costs. One of ordinary skill will also appreciate that improved slag consistency increases safety to operators with further benefits including easier and less time to remove all slag during iron casting production. One of ordinary skill will also appreciate that slag reduction is evidence of reduction of oxidation during the iron melting process. Further the results 50a indicate increased fluidity which has the benefit of reducing defects with an additional benefit of reducing melt energy costs as superheat is reduced. Further, the results 50a indicate an increased nodule count and nodularity improved with supporting the conclusion that the mechanical properties of the iron casting produced are improved.

[0077] For data comparison purposes, heats 5, 6, 7, 10 and 11 used an aggregate additive 10a as disclosed herein (referenced as (New Blend or NB throughout the data sets) at the same addition rate producing similar reductions in slag weight and increases in fluidity, as supported by at least the Slag data and charts summarized at page 2; the Fluidity data, charts and tables as found at FIGS. 4-7 and summarized in Tables A and B. As supported by the pilot results 50 of Appendix A, measured slag weight was reduced. FIG. 4 is an illustrative graph plotting a comparison of the Slag Generated per Heat. Table B summarizes the percent (%) increase in fluidity for heats 2-11 over the baseline labeled as heat 1.

[0078] For purposes of the pilot study, heats 1, 3, 5, 6, 8, 9, 10, 11 and were Cold starts. A Cold furnace indicates a room temperature lining at the beginning of the melting process. Heats 2, 4, and 7 were Hot starts. A Hot furnace indicates the lining was at a high temperature at the beginning of the melting process, i.e. it had been preheated from a previous heat.

[0079] As referenced in the pilot study 50, New Blend 1 (NB1) was formulated to contain SiC and low sulfur carbon raiser (Desulco). It was blended in a ratio to match OB chemistry (66.6% graphite, 33.4% SiC to achieve 80% C, 20% Si). Further, Graphite and SiC were crushed and sieved to under 40 mesh. The material was then screened and blended to match OB sieve analysis.

[0080] As referenced in the pilot study 50, New Blend 2 (NB2) was formulated to contain SiC and low sulfur carbon raiser (Desulco) as well. Further, it was blended in a ratio to match OB chemistry (66.6% graphite, 33.4% SiC to achieve 80% C, 20% Si). No special screening or preparation was completed, it was blended As-Is sizing.

[0081] As referenced in the pilot study 50, New Blend 3 (NB3) was formulated to slow down reaction time. It also contained SiC and low sulfur carbon raiser (Desulco) blended in ratio to match OB chemistry (66.6% graphite, 33.4% SiC to achieve 80% C, 20% Si). It was blended with only roughest screened (#6) materials.

[0082] As referenced in the pilot study 50, New Blend 4 (NB4) tested SiC/C content with low sulfur carbon raiser only. It was used as provided condition for screen and distribution.

[0083] As referenced in the pilot study 50, New Blend 5 (NB5) incorporated a test with slurry binder with the same formulation as base blend as NB3 and mixed with clay slurry as a binding agent. As referenced in the pilot study 50, New Blend 6 (NB6) was subject to industrial scale blending conditions and used a second graphite supplier allowing for evaluation of the new slurry concentration, industrial blending procedure, and second graphite supplier.

[0084] FIG. 5 is an illustrative plotting Slag Weight for Cold Start heats (1, 3, 5-6, 9, 10-11).

[0085] FIG. 6 is an illustrative plotting of Fluidity across heats 1-11.

[0086] Table B summarizes the percent (%) change of fluidity across heats 1-11.

[0087] FIG. 7 is an illustrative plotting of the fluidity data across heats 1-11.

[0088] FIG. 8 compares the expected fluidity versus the measured fluidity in support of validation of the pilot data produced.

[0089] FIG. 9 is an illustrative plotting of the fluidity data across heats 1-11.

[0090] Further, slag consistency was improved. FIG. 12A and FIG. 12B are images are qualitatively confirming the slag consistency of heat 1 (1334 grams of slag) versus heat 5 (670 grams of slag). FIGS. 13A and 13B are images of partially filled fluidity spirals for heats 3 and 4 (approximately 1350 mm) versus filled fluidity spirals for heats 5, 6, 10 and 11 (1500 mm).

[0091] Table B summarizes the nodule count and nodularity of the iron casting produced for heats 2-11 over the baseline labeled as heat 1.

[0092] FIG. 10 is an illustrative plotting of tensile test results across heats 1-11.

[0093] A summary analysis of Heats 1-4 leads to the conclusion that increasing amounts of the OB (additive 10) resulted in reduced slag weight (FIG. 5), increases in fluidity (FIG. 7) and increases in elongation. This data indicates potential reductions in oxide inclusions which increase viscosity and decrease ductility. Tensile and yield strengths remained relatively constant. Further, the data indicates an increase in both nodule count and nodularity. (See FIGS. 9 and Table C). Analysis of Heat 4 versus Heat 3 data suggests a marginal reduction in slag weight and increase in fluidity as well as a reduction in nodule count. Further, this data suggests that the additive 10 at a proscribed rate of 0.30% by weight of the charge mix weight was the target addition rate as additional benefits from increasing the weight percent of additive were not indicated.

[0094] A summary analysis of Heat 5 leads to the conclusion that the NB1 outperformed OB in reduction of slag weight and increase in fluidity. Both tensile and yield strengths increased. Elongation decreased as a result of increased tensile properties.

[0095] A summary analysis of Heats 6-7 leads to the conclusion that the Heat 6 performed within the same range as Heat 5. Similar slag weight and filled fluidity spiral. Heat 7 performed within the same range as Heats 5 and 6.

[0096] A summary analysis of Heat 8 leads to the conclusion the roughest sizing of the OB produced more slag and had reduced fluidity compared to Heat 6 (standard sizing). Further, Heat 8 was more difficult to deslag, similar to the initial heats that were not treated or only partially treated. Thus, sizing of the additive material has an influence on its performance in the iron production process. However, Heat 8 still performed better than Heat 3 (standard sizing, OB) with reducing slag weight and about the same in fluidity results. A summary analysis of Heat 9 leads to the conclusion that an additive blend which is all carbon, with no Silicon carbide (SiC) produced more slag and had reduced fluidity compared to Heat 6 (standard composition of additive 10 referenced as NB). This data indicates that the presence of SiC has an influence on its performance. Note: Heat 9 still outperformed Heat 3 (standard sizing, OB) and Heat 8 (coarse NB) with reducing slag weight and increasing fluidity. Heat 10 produced the same amount of slag reduction as cold start Heats 5 and 6. Heat 10 resulted in a full fluidity spiral as did Heats 6 and 7. Heat 5 fluidity result was longer than all oxidation reduction additive heats and nearly full as well.

[0097] Heat 11 produced the same amount of slag reduction as cold start Heats 5, 6, and 10. Heat 11 resulted in a full fluidity spiral as did Heats 6, 7, and 10. Heat 11 validated slurry change, production blending method, and a second graphite supplier produces results consistent with previously successful heats. A summary analysis of Heat 11 leads to the conclusion the configuration of the additive 10 as an aggregate 10 further improves oxidation reduction.

[0098] Table C summarizes the additive formulation used in the iron production process for heats 1-11. FIG. 11 is an illustrative plotting for the durability of the various additive blends for heats 1-11. Analysis of blend segregation, as supported by Heat 8, suggests material size of the additive 10 is related to oxidation reduction performance. Further, as supported by Heat 9, the composition chemistry (i.e. additive components selected and weight percent of each additive component) effects oxidation reduction performance with distribution of silicon carbide in graphite and adherence of graphite to silicon carbide particles improving oxidation reduction performance.

[0099] In at least one embodiment of the additive 10, an aggregate may be generated from the combination of water, bentonite slurry, colloidal graphite and colloidal silica.

[0100] FIG. 14 is a visual confirmation of the fluidity thin wall study completed during the pilot study. See also FIGS. 12A and 12B providing a qualitative visual comparison of the reduction of slag between heat 1 and heat 5 (1334 grams vs. 670 grams). The data, pictures and tables found at FIGS. 4-6 and Tables A-D support the conclusion that the iron casting produced with the additive 10 and additive aggregate 10a is improved versus the prior art iron castings made without the additive 10 or additive aggregate 10a. The composition data presented at page 27-29 is further evidence that use of the additive 10 and or additive aggregate 10a produces higher quality iron castings as represented by the percentage of alloys present (Cu, Mn, Si and C). For data comparison purposes, heats 1-4 used either no additive (baseline) or additive common in the prior art (OB) comprised of a combination of carbon graphite and Silicon carbide (SiC), without the presence of bentonite or any binder. As further described at Tables D-E, the amount of additive 10 used in the casting process was between 0.28-0.30 weight percent of the charge mix mass. (Compare Heats 10 and 11 to Heats 1-9)

[0101] Table A provides a summary of Foundry Lab Results. The results of the pilot study 50 support the conclusion that at least one embodiment of the disclosed oxidation reduction additive 10 comprised of the combination of silicon carbide 7, bentonite 8 and carbon graphite 9, when introduced to the charge mix 20 during iron melting, reduced resulting oxidation. The results of the pilot study 50 also support the conclusion that at least one embodiment of the disclosed oxidation reduction additive 10, structured as an aggregate 10a, comprised of the combination of silicon carbide 7a, bentonite 8a and carbon graphite 9a, when introduced to the charge mix 20 during iron melting, also reduced resulting oxidation. (Compare Heats 10 and 11 to Heats 5-9) Further, the at least one embodiment of the oxidation reduction additive 10, configured as an aggregate 10a, outperformed both the oxidation reduction additive 10, not configured as an aggregate, and the prior art blend (OB). (Compare Heats 10 and 11 to Heats 5-9 and Heats 1-4)

[0102] As measured, use of the additive 10 reduced slag weight with the benefit of reducing disposal costs. As measured, slag consistency was improved. This increases operator safety as the slag is easier to remove and increases operator efficiency as less time is needed to remove slag. As measured, fluidity was increased with the benefit of reduced defects and superheat with the ultimate benefit of reducing melt energy costs. As measured, nodule count increased along with nodularity with the benefit of improved mechanical properties of the produced casting. See Heats 5, 6, 7, 10, 11 for data comparison purposes, which are all New Blend (i.e. at least one embodiment of the oxidation reduction additive 10) at same addition rate and showed similar reductions in slag weight and increases in fluidity.

[0103] Having described preferred aspects of the various processes, apparatuses, and products made thereby, other features of the present disclosure will undoubtedly occur to those versed in the art, as will numerous modifications and alterations in the embodiments and/or aspects as illustrated herein, all of which may be achieved without departing from the spirit and scope of the present disclosure. Accordingly, the methods and embodiments pictured and described herein are for illustrative purposes only, and the scope of the present disclosure extends to all processes, apparatuses, and/or structures for providing the various benefits and/or features of the present disclosure unless so indicated in the following claims.

[0104] While the process, process steps, components thereof, apparatuses therefor and results produced according to the present disclosure have been described in connection with preferred aspects and specific examples, it is not intended that the scope be limited to the particular embodiments and/or aspects set forth, as the embodiments and/or aspects herein are intended in all respects to be illustrative rather than restrictive. Accordingly, the processes and embodiments pictured and described herein are no way limiting to the scope of the present disclosure unless so stated in the following claims.

[0105] Although several figures are drawn to accurate scale, any dimensions provided herein are for illustrative purposes only and in no way limit the scope of the present disclosure unless so indicated in the following claims. It should be noted that the processes, software and methods disclosed are not limited to the specific embodiments pictured and described herein, but rather the scope of the inventive features according to the present disclosure is defined by the claims herein. Modifications and alterations from the described embodiments will occur to those skilled in the art without departure from the spirit and scope of the present disclosure.

[0106] Any of the various features, components, functionalities, advantages, aspects, configurations, process steps etc. of a computerized transaction, a process step, and/or an application, may be used alone or in combination with one another depending on the compatibility of the features, components, functionalities, advantages, aspects, configurations, process steps, process parameters, etc. Accordingly, an infinite number of variations of the present disclosure exist. Modifications and/or substitutions of one feature, component, functionality, aspect, configuration, process step, process parameter, etc. for another in no way limit the scope of the present disclosure unless so indicated in the following claims.

[0107] It is understood that the present disclosure extends to all alternative combinations of one or more of the individual features mentioned, evident from the text and/or drawings, and/or inherently disclosed. All of these different combinations constitute various alternative aspects of the present disclosure and/or components thereof. The embodiments described herein explain the best modes known for practicing the apparatuses, methods, and/or components disclosed herein and will enable others skilled in the art to utilize the same. The claims are to be construed to include alternative embodiments to the extent permitted by the prior art.

[0108] Unless otherwise expressly stated in the claims, it is in no way intended that any process or method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is no way intended that an order be inferred, in any respect. This holds for any possible non-express basis for interpretation, including but not limited to: matters of logic with respect to arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; the number or type of embodiments described in the specification. To aid the Patent Office and any readers of any patent issued on this application in interpreting the claims appended hereto, applicants wish to note that they do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112 (f) unless the words means for or step for are explicitly used in the particular claim.