8th International Congress on Science and Technology of Ironmaking - ICSTI 2018

In Egypt, the crude steel production has increased significantly with higher growth rate in the past years of the 21th century. Furthermore, many mill steel companies have been established for steel processing. With the increase in steel production and steel processing, a large amount of waste materials (slag, dust and mill scale) are produced. Mall scale is one of these waste materials produced during preheating of steel slabs and billets before hot rolling in all iron and steel companies and its specific production is about 20-40 kg/ ton of hot rolled product. The mill scale generated from the hot rolled steel products in Egyptian integrated and processing steel companies is amounted 200000 tons annually. This bi-product mill scale is mainly iron oxides and considered a rich iron source. On the other hand, high purity pig iron is used in the production of ductile cast iron. Its consumption is about 25% of the produced ductile cast iron. All needs of high purity pig iron for Egyptian industry are imported. This work aims at recycling of mill scale by adjusting smelting process to produce high purity pig iron. Different heats of smelting process were carried out at submerged arc furnace using different reductants and different fluxing materials to adapt an economic smelting process for producing high purity pig iron with minimum Mn, P, S and other impurities and attain the highest recovery and output. By using the optimum condition, high purity pig iron is obtained with chemical composition conforming the requirements to be used in the production of ductile cast iron. The industrial application of the produced high purity pig iron revealed good mechanical properties of the cast product conforming the requirements of ductile cast iron and the microstructure observation confirmed the obtained mechanical properties.