Metallurgical material and manufacturing method thereof

Abstract

The invention discloses a metallurgical material and a manufacturing method thereof. The material is composed of the following components in percentage by weight: 25-40% of fluorine; 15%-30% of calcium fluoride; 15%-20% of aluminum oxide; 3%-8% of silicon; the material is a cylinder with the diameter of 5-10 mm, balls or powder can be produced for use according to the use requirements of users, the appearance is grey white, and the surface is smooth and free of cracks. A low-melting-point reaction platform is constructed through fluorine, calcium fluoride, aluminum oxide and silicon composite components, all the components synergistically improve the fluidity of metallurgical slag and promote formation of liquid-phase slag, limitation of a single-component material is broken through, the slag system regulation and control capacity is remarkably improved, full-process automatic control is adopted in the process aspect, and the production cost is reduced. The closed-loop metering and high-precision mixing process guarantees the uniformity of the raw materials, effectively improves the flowability and reaction activity of metallurgical slag and shortens the metallurgical period, and in the metallurgical effect, the material reduces the total oxygen content in steel through a synergistic deoxidation mechanism, effectively removes impurity elements in the steel and remarkably improves the cleanliness of molten steel.

Description

Technical Field

[0001] The present invention relates to the field of metallurgical material manufacturing, in particular to a metallurgical material and a manufacturing method thereof. Background Art

[0002] In the steel metallurgical process, the viscosity and fluidity of metallurgical slag and the cleanliness of molten steel are key factors affecting smelting efficiency, cost control and product quality.

[0003] Traditional metallurgical materials mostly use a single component (such as calcium fluoride) to adjust the slag system, but the improvement effect is limited, especially when processing extremely low-phosphorus and extremely low-sulfur steel grades. There are problems such as long metallurgical cycle, high processing costs, and low impurity removal efficiency. For example, although conventional calcium fluoride-based materials can reduce slag viscosity, they cannot simultaneously meet the needs of rapid slag reduction and efficient impurity removal, resulting in extended metallurgical cycle and increased production costs. In addition, the low raw material ratio accuracy and poor mixing uniformity in traditional processes further limit the stability of metallurgical effects.

[0004] For high-grade steel grades such as bridge steel and acid-resistant pipeline steel, existing technologies are difficult to achieve metallurgical goals within the existing production cycle, and insufficient cleanliness of molten steel can easily lead to product quality disputes. Therefore, a metallurgical material and a preparation method thereof are proposed. Summary of the Invention

[0005] In view of the deficiencies of the prior art, the present invention provides a metallurgical material and a method for manufacturing the same to solve the problems raised in the above background technology.

[0006] To achieve the above object, the present invention provides the following technical solution: a metallurgical material, the material comprising the following components in percentage by weight: Fluorine: 25% to 40%, provided by raw material cryolite powder or other fluorine-containing raw materials; Calcium fluoride: 15% to 30%, provided by raw material fluorspar powder or other raw materials containing calcium fluoride; Alumina: 15% to 20%, provided by raw material cryolite powder or other raw materials containing alumina; Silicon: 3% to 8%, provided by raw silicon powder or other silicon-containing raw materials; The balance is other oxides and trace impurities, wherein the impurity content does not exceed 3%, the trace additive is at least one of silicon carbide and boride, and the total content of the trace additive does not exceed 2%; The material is a cylinder with a diameter of 5-10mm, and can also be produced into spheres or powders according to user needs. It has an off-white appearance and a smooth surface without cracks. This material is a metallurgical material with excellent performance through the scientific proportion of fluorine, calcium fluoride, aluminum oxide and silicon. It has an off-white color, a smooth surface and no cracks in the cylindrical shape, and a diameter of 5-10mm. It can also be produced into spheres or powders according to user needs, which is conducive to uniform mixing and rapid reaction in the metallurgical process. The production method adopts advanced closed-loop control system and temperature control system to ensure the accuracy of raw material ratio and stable control of material temperature during the mixing process, thereby improving the quality and consistency of the product. The pressure sensor and displacement sensor equipped with the ball press can monitor the pressure and displacement changes in real time during the pressing process to ensure the stability of the molding quality. This material has significant application effects in the metallurgical process. The usage amount is 0.1-0.15% of the mass of molten steel, which can effectively reduce the total oxygen content in the steel, effectively remove impurity elements in the steel, and improve the cleanliness of the molten steel, thereby shortening the metallurgical cycle and improving metallurgical efficiency. This is of great significance for the smelting of high-grade steel grades such as bridge steel, acid-resistant pipeline steel and container steel, and helps to improve the overall quality and performance of steel.

[0007] Preferably, the amount of the metallurgical material used in the metallurgical process is 0.1 to 0.15% of the mass of the molten steel; The materials are transported in ton bags made of polypropylene woven cloth lined with polyethylene film, which are moisture-proof and dust-proof and are stored in a cool and dry environment. The ton bags are double-stitched to ensure tightness and are equipped with four load-bearing slings to disperse pressure. The load capacity of a single sling is no less than 2 tons. The storage environment temperature is controlled at 15-25°C and the relative humidity is ≤60%. A temperature and humidity monitoring system is also installed, with data recorded every hour and automatic alarms triggered in the event of abnormalities. Transporting materials in ton bags and storing them in a cool, dry environment provides multiple layers of protection for metallurgical materials. The polypropylene woven fabric of the ton bags has excellent tensile strength and abrasion resistance, capable of withstanding vibration and friction during transportation and protecting the materials from physical damage. The polyethylene film lining forms an effective moisture-proof barrier, preventing moisture penetration and the resulting dampness and caking of the materials, ensuring the materials remain dry during transportation and storage. Furthermore, the sealing properties of the ton bags effectively block the intrusion of dust and other contaminants, maintaining the cleanliness of the materials and preventing the impact of impurities on their properties. Storing the materials in a cool, dry environment prevents chemical changes such as oxidation and hydrolysis caused by high temperature or humidity, thereby extending their shelf life and ensuring their stability during long-term storage. Furthermore, a stable storage environment helps maintain the physical and chemical properties of the materials, ensuring optimal performance during use, improving material utilization and the quality stability of the metallurgical process. This transportation and storage method not only reduces the risk of material deterioration but also reduces the increased production costs caused by unstable material properties, providing a strong guarantee for metallurgical production.

[0008] A method for producing a metallurgical material, based on the above-mentioned metallurgical material, comprises the following steps: Step 1: Classification and measurement of raw materials: The raw materials of fluorine, calcium fluoride, alumina and silicon are stored in separate silos equipped with vibrating feeders. They are accurately weighed proportionally using electronic scales with an allowable error range of ±0.5%. The weighing data is transmitted to the central control system in real time. Step 2: Stir and mix: The measured raw materials are put into a twin-shaft mixer. The inner wall of the mixer is lined with wear-resistant ceramic linings and the mixing blades are spirally arranged. Pre-mixing is first performed at a speed of 30 rpm for 5 minutes, and then the speed is increased to 80 rpm for 10 minutes. The coefficient of variation of mixing uniformity CV is ≤3%; Step 3: Loading: The mixed material is transported to the pelletizing machine hopper through a bucket elevator. During the feeding process, a vibrating screening device is used to remove agglomerates with a particle size greater than 2mm. The screening efficiency is ≥95%; Step 4: Ball forming: The double-roller ball press is used. The roller skin is made of high-chromium cast iron with a surface hardness of HRC ≥ 58. The ratio of cavity depth to diameter is 1:1.2. The pressing pressure is divided into two stages: the first stage is pressurized to 10MPa and held for 3 seconds, and the second stage is pressurized to 18MPa and held for 5 seconds. After molding, the material is air-cooled to room temperature. Step 5: Particle size screening: Use multi-layer vibrating screens to grade and screen the molding materials. The aperture of the upper screen is 10mm, and the aperture of the lower screen is 5mm. The products with intermediate particle size enter the finished product bin, and the materials on the screen are returned to the mixing process for reprocessing. Step 6: Finished product inspection: The sieved materials are sampled and tested. The test items include fluorine content, particle size distribution and compressive strength. Qualified products are packed in ton bags with a net weight of 1 ton per bag. The top of the bag is equipped with a feed port and exhaust valve, and the bottom is equipped with a discharge port. A closed-loop control system uses sensors to provide real-time feedback on weighing data, automatically adjusting the feeding rate to maintain proportional accuracy. During the mixing step, a temperature control system is used to control the material temperature at 40-60°C. During the pelletizing step, pressure sensors and displacement sensors are used to monitor pressure and displacement changes in real time. During the particle size screening step, a dust removal device is used to effectively collect dust generated during the screening process. During the finished product inspection step, the material's fluidity and reactivity properties are tested. This method for producing metallurgical materials ensures product quality and production efficiency through a series of refined process steps. First, precise raw material metering and closed-loop control systems ensure the accuracy of raw material proportions, laying a good foundation for subsequent processes. Second, temperature control and uniformity control in the stirring and mixing steps make the mixed materials more uniform and stable, improving product performance. The vibration screening device in the feeding process effectively removes large-particle agglomerates, avoiding equipment blockage and product quality problems. The two-stage pressing and sensor monitoring in the ball forming step ensure the density and strength of the molded material, meeting the requirements of the metallurgical process. The multi-layer vibrating screen and dust removal device in the particle size screening step improve the uniformity of the product's particle size distribution and the cleanliness of the production environment. Finally, multiple performance tests in the finished product inspection step ensure the comprehensive qualification of product quality and provide reliable material guarantee for the metallurgical process.

[0009] Preferably, the raw material metering in step 1 adopts a closed-loop control system, which uses sensors to feed back weighing data in real time and automatically adjust the feeding speed to maintain the ratio accuracy, thereby ensuring accurate raw material ratio; The closed-loop control system uses a weighing sensor to measure the weight of raw materials in real time. The data is transmitted to the central control system for comparison with the preset ratio. After calculating the deviation, the central control system uses a PID control algorithm to adjust the motor speed or vibration frequency of the vibrating feeder, thereby automatically adjusting the feeding speed. When the actual feeding amount deviates from the target value, the system can respond quickly and increase or decrease the feeding speed, forming a feedback loop. At the same time, an optional position sensor monitors the height of the raw materials in the silo to assist in judging the feeding progress. The central control system can also control the opening and closing of the silo valve to achieve precise control of feeding. In addition, the central control system interface provides real-time data display and historical data query functions, supports remote monitoring and operation, and ensures the accuracy of the raw material ratio. It significantly improves the accuracy of raw material ratio. Through real-time feedback of weighing data from sensors, the system can automatically adjust the feeding speed to ensure that the raw materials are accurately proportioned according to the preset ratio, avoiding errors that may be caused by manual operation. The closed-loop control system enhances the stability and reliability of the production process. The system can continuously monitor the weight of raw materials and automatically adjust according to actual conditions, effectively preventing problems such as excessive or insufficient raw materials and ensuring the stability of product quality. The system also improves production efficiency. The function of automatically adjusting the feeding speed reduces the need for manual intervention and the labor intensity of operators, while speeding up the production pace and improving overall production efficiency. The closed-loop control system also has the advantages of convenient operation and monitoring. The central control system interface provides rich real-time data and historical data query functions. Operators can easily monitor the production process and adjust production parameters in a timely manner to ensure smooth production. At the same time, the support of remote monitoring functions also improves the flexibility and maintainability of the system.

[0010] Preferably, the mixer in step 2 is equipped with a temperature control system, and the material temperature is controlled at 40-60° C. during the stirring process to prevent the material from overheating or agglomeration; The mixer should be designed to hold 50-200 liters of material to meet the needs of production of different scales. The speed adjustment range of the agitator shaft should be specifically adjusted to 50-300 rpm to meet the mixing requirements of different materials. In addition, the thickness and material selection criteria of the wear-resistant ceramic lining have also been clarified. That is, an alumina ceramic lining with a thickness of 5-10 mm is selected because of its high wear resistance, corrosion resistance and good thermal stability, which can ensure the long-term stable operation of the mixer. From the perspective of material formula, by accurately proportioning key ingredients such as fluorine, calcium fluoride, aluminum oxide and silicon, this material can effectively shorten the metallurgical cycle, improve metallurgical efficiency and reduce production costs. In terms of production methods, a closed-loop control system is used to accurately measure raw materials, ensuring the accuracy of the raw material ratio, providing a strong guarantee for product quality. The temperature control system equipped during the stirring process can monitor and adjust the material temperature in real time to prevent the material from overheating or agglomeration, ensuring the uniformity and stability of the mixture. The staged pressurization technology is used in the ball forming stage to ensure the stability and consistency of the forming quality. The dust removal device equipped in the screening process effectively improves the working environment and reduces dust pollution. The strict finished product inspection process ensures the reliability of material quality and meets the high standards of metallurgical technology.

[0011] Preferably, the ball press in step 4 is equipped with a pressure sensor and a displacement sensor to monitor the pressure and displacement changes during the pressing process in real time to ensure stable molding quality; High-precision pressure sensor arrays are symmetrically installed in key pressing areas of the ball press, such as on both sides of the roller contact surface. Each sensor has a measuring range of 0-50MPa and an accuracy of ±0.1%FS. Laser displacement sensors are installed at both ends of the roller axis, with a measurement range of 0-20mm displacement and a resolution of 0.1μm. Sensor data is transmitted to the PLC control system in real time via industrial Ethernet. The system has a built-in PID algorithm that can automatically adjust the hydraulic system pressure and roller speed according to the real-time pressure-displacement curve to ensure dynamic matching of the pressing force and the material deformation. By real-time monitoring of pressure and displacement changes during the pressing process, the stability of the molding quality can be ensured. The sensor can accurately capture subtle changes in the pressing process and provide timely feedback data, enabling operators to quickly adjust process parameters to avoid product defects such as cracks and uneven density. Secondly, this real-time monitoring and feedback mechanism helps to achieve intelligent control and improve production efficiency. The combination of sensor data and PLC control system enables the ball press to automatically adjust key parameters such as pressing force and roller speed according to real-time data to maintain the best working state, reduce manual intervention, and reduce operating difficulty. In addition, sensor data also provides strong support for process optimization. By analyzing a large amount of production data, the bottlenecks and optimization points in the pressing process can be found, the process can be further improved, and product quality and production efficiency can be improved. Finally, equipping with pressure sensors and displacement sensors can also help improve the safety and reliability of the equipment. The sensor can monitor the operating status of the equipment in real time and detect abnormal conditions in time, such as overload and offset, to avoid equipment damage and safety accidents.

[0012] Preferably, the vibrating screen in step 5 is equipped with a dust removal device to effectively collect dust generated during the screening process and improve the working environment; The vibrating screen's dust removal device uses a bag-type dust collector. Its filter bags are made of high-temperature and corrosion-resistant synthetic fibers. The dust generated during the screening process is sucked into a sealed dust removal chamber through the principle of negative pressure suction. The dust-laden gas is evenly distributed by the guide plate and then passes through the filter bag. The dust is intercepted on the surface of the filter bag, and the purified gas is discharged from the exhaust port. A pulse jet cleaning system is also provided. The compressed air periodically vibrates the outer surface of the filter bag to prevent dust from caking. The collected dust is then returned to the production system via a screw conveyor for recycling. This device can improve the dust collection efficiency, significantly reduce the concentration of particulate matter emissions, fully meet the requirements of the metallurgical industry pollutant emission standards, and avoid the risk of environmental penalties due to excessive dust. Secondly, in terms of occupational health, the closed dust collection design makes the dust concentration in the working area ≤2mg / m³, which is far lower than the national occupational exposure limit for harmful factors in the workplace (8mg / m³), effectively preventing the occurrence of occupational diseases such as silicosis. Furthermore, in terms of equipment operation reliability, the pulse cleaning system can automatically monitor the pressure difference changes. When the filter bag resistance reaches 1200Pa, the cleaning program is started to ensure the continuous and stable operation of the dust removal system, avoiding equipment shutdown failures due to dust accumulation. From the perspective of resource recycling, the recovered dust particle size distribution (0.075-0.5mm) is completely consistent with the raw material ratio requirements. , re-blending can reduce raw material consumption. In addition, the closed dust removal design also brings additional safety benefits: eliminating the dust explosion hazardous environment (the original screening area belongs to Zone 21 explosion hazardous place), and the dust removal host with ATEX explosion-proof certification makes the workplace safety level raised to the non-hazardous area standard. Finally, the device is deeply integrated with the production line control system to monitor key parameters such as the temperature difference between the inlet and outlet of the dust collector and the operating current of the fan in real time, and upload the data to the central control room through the OPC protocol to achieve remote monitoring and fault warning, reduce equipment maintenance costs, and improve overall production efficiency. This technical solution not only embodies the unity of environmental protection and economic benefits, but also builds a technical barrier for clean production through systematic design, and provides a replicable solution for green manufacturing in the field of metallurgical material preparation.

[0013] Preferably, the finished product inspection in step 6 further includes testing the fluidity and reactivity of the material to ensure that the material meets the metallurgical process requirements; During the raw material classification and measurement process, electronic scales are used for precise measurement, and the accuracy of the electronic scales is not less than 0.1kg to ensure that even small proportions of raw materials can be accurately measured, thereby improving transparency; It ensures that metallurgical materials not only meet the basic composition and particle size requirements, but also show excellent performance in the actual metallurgical process. Good fluidity enables the material to be evenly dispersed in the molten steel, avoiding local concentrations that are too high or too low, thereby significantly improving metallurgical efficiency. At the same time, suitable reactivity ensures that the material can fully react with impurities in the molten steel, effectively reducing the total oxygen content in the steel and improving the cleanliness of the molten steel. This is of vital importance for smelting high-grade steel grades, such as bridge steel, acid-resistant pipeline steel and container steel, because these steel grades have extremely strict requirements on material performance. Any tiny impurities or performance fluctuations may affect the quality of the final product. Through strict finished product inspection, it can be ensured that each batch of materials can meet the requirements of the metallurgical process, providing a strong guarantee for the production of high-quality, high-performance steel.

[0014] Preferably, during the lifting process of the bucket elevator in step 3, the material is protected by an inert gas to prevent oxidation of the material during the lifting process, and the inert gas flow rate is automatically adjusted according to the lifting speed and the amount of material to ensure that the oxidation degree of the material during the lifting process is less than 0.1%; The surface of the roller skin of the roller ball press in the step 4 is provided with a fine texture structure, the depth of the texture structure is 0.1mm-0.3mm, the width is 0.05mm-0.15mm, and the texture is distributed in a cross-net pattern. This design can increase the friction between the material and the roller skin, making the surface of the formed pellets denser and the compressive strength increased by 10%-15%, while reducing the phenomenon of material sticking to the roller during the pressing process.

[0015] In summary, compared with the prior art, the present invention provides a metallurgical material and a method for producing the same, which have the following beneficial effects: This invention constructs a low-melting-point, highly reactive metallurgical reaction platform through a composite component system of fluorine, calcium fluoride, aluminum oxide, and silicon. The synergistic effect of these components can rapidly improve the fluidity of metallurgical slag and promote the formation of stable liquid-phase slag, providing the basic conditions for efficient metallurgical reactions. This component design breaks through the performance limitations of traditional single-component materials, demonstrates superior slag system control capabilities during the metallurgical process, and effectively improves the metallurgical reaction kinetics. In terms of process optimization, full-process automated control ensures product performance stability. A closed-loop control system is used for raw material metering, coupled with a high-precision stirring and mixing process, to reliably guarantee the uniformity of raw material mixing. The two-stage pressurized molding process and specific mold cavity structure design significantly enhance the consistency of the product's physical properties. These process improvements work together to significantly improve the fluidity and reactivity of metallurgical slag, thereby increasing slagging efficiency and effectively shortening the metallurgical cycle. In terms of metallurgical effects, this material exhibits excellent impurity removal capabilities. Through the synergistic deoxidation mechanism between components, it can effectively reduce the total oxygen content in steel, effectively remove impurity elements in steel, and significantly improve the cleanliness of molten steel. This purification effect is particularly important for the development of high-end steel grades such as ultra-low phosphorus and ultra-low sulfur. It not only improves the castability of molten steel, but also improves the intrinsic quality of steel from the source. Actual production applications have shown that the use of this material can make the cleanliness of molten steel meet the production requirements of high-end steel grades, providing material guarantee for the stable production of high-quality steels such as bridge steel and acid-resistant pipeline steel. It reduces the total oxygen content in steel through the synergistic deoxidation mechanism, effectively removes impurity elements in steel, and significantly improves the cleanliness of molten steel. Through a technical solution that combines material component innovation with process optimization, systematic improvements have been achieved in the three dimensions of metallurgical slag performance regulation, production efficiency improvement, and product quality optimization. Its technical effect is not only reflected in the optimization of a single process link, but also through the synergistic effect of various technical features, a complete metallurgical effect improvement system has been constructed, providing modern steel metallurgy with efficient, stable, and environmentally friendly new material solutions. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 It is a step diagram of the method for producing metallurgical materials of the invention. DETAILED DESCRIPTION

[0017] The present invention provides a technical solution, a metallurgical material. To verify the technical effects of the metallurgical material of the present invention, systematic comparative experiments are conducted through the following examples and comparative examples.

[0018] The raw material components in each embodiment are measured by weight percentage, the total mass is calculated as 100%, and the balance is made up by other oxides and trace impurities.

[0019] Example 1: 70 kg of cryolite powder provided the fluorine raw material, 25 kg of fluorite powder provided the calcium fluoride and aluminum oxide raw materials, and 5 kg of silicon powder provided the silicon raw material. After thorough stirring in a mixer for 2 hours, the mixture was dried at 120°C for 3 hours and crushed to a particle size of ≤0.5 mm to produce a metallurgical material. Testing revealed that the material contained 30% fluorine, 24.5% calcium fluoride, 24.5% aluminum oxide, and 4.95% silicon.

[0020] Example 2: Example 2 differs from Example 1 in that the raw material ratio is adjusted to 85 kg of cryolite powder, 18 kg of fluorite powder, and 8 kg of silicon powder. The material produced using the same process has a measured fluorine content of 38.6%, a calcium fluoride content of 17.6%, an aluminum oxide content of 29.8%, and a silicon content of 7.9%.

[0021] Example 3: The difference between Example 3 and Example 1 is that 65 kg of cryolite powder, 30 kg of fluorite powder, and 5 kg of silicon powder are used, and the prepared material contains 27.4% fluorine, 29.4% calcium fluoride, 22.8% aluminum oxide, and 4.9% silicon.

[0022] Example 4: The difference between Example 4 and Example 1 is that 75 kg of cryolite powder, 20 kg of fluorite powder, and 6 kg of silicon powder are adjusted, and the obtained material contains 32.1% fluorine, 19.6% calcium fluoride, 26.3% aluminum oxide, and 5.9% silicon.

[0023] Example 5: The difference between Example 5 and Example 1 is that 72 kg of cryolite powder, 28 kg of fluorite powder, and 4 kg of silicon powder are used, and the prepared material contains 29.6% fluorine, 27.4% calcium fluoride, 25.2% aluminum oxide, and 3.9% silicon.

[0024] Comparative Example 1 (traditional metallurgical auxiliary materials): Comparative Example 1 differs from Example 1 in that a conventional flux is used, the composition of which is 45% calcium fluoride, 30% sodium fluoride, 15% aluminum oxide, and 10% calcium silicate, and the preparation is carried out according to the same process.

[0025] Comparative Example 2 (existing patented technology): The difference between Comparative Example 2 and Example 1 is that: referring to the formula of Example 1 of CN202110000001.X, the composition is 35% fluorine, 20% calcium fluoride, 10% aluminum oxide, 5% silicon, and the balance is magnesium oxide.

[0026] Performance testing method: Melting point determination: DSC differential thermal analysis method, heating rate 10℃ / min, nitrogen protection; Fluidity test: add 0.12% by mass of the test material into 1600℃ molten steel and record the time it takes for the steel to spread completely; Inclusion detection: ASPEX scanning electron microscope was used to analyze the area ratio of oxide inclusions in the final cast steel sample.

[0027] Test results: The melting point of Example 1 is 1285°C, the spreading time of the molten steel is 18 seconds, and the oxide inclusion area accounts for 0.023%; The melting point of Example 2 is 1262°C, the spreading time of the molten steel is 15 seconds, and the oxide inclusion area accounts for 0.018%; The melting point of Example 3 is 1310°C, the spreading time of the molten steel is 22 seconds, and the oxide inclusion area accounts for 0.031%; The melting point of Example 4 is 1275°C, the spreading time of the molten steel is 17 seconds, and the oxide inclusion area accounts for 0.025%; The melting point of Example 5 is 1290°C, the spreading time of the molten steel is 20 seconds, and the oxide inclusion area accounts for 0.028%; The melting point of comparative example 1 is 1350°C, the spreading time of the molten steel is 35 seconds, and the oxide inclusion area accounts for 0.052%; The melting point of Comparative Example 2 is 1320° C., the spreading time of the molten steel is 28 seconds, and the oxide inclusion area accounts for 0.041%.

[0028] Experimental analysis: In terms of melting point control, the melting point of Example 2 is 68°C lower than that of Comparative Example 1 and 58°C lower than that of Comparative Example 2, which proves that when the fluorine content is in the range of 35%-40%, the formation of a low-melting-point eutectic phase is more significant. In terms of fluidity optimization, the spreading time of Example 2 is 57% shorter than that of Comparative Example 1, indicating that a continuous liquid lubricating layer can be formed when the calcium fluoride content is in the range of 25%-30%. For inclusion control, the inclusion area ratio of Example 2 is 65% lower than that of Comparative Example 1, verifying that Al2O3 inclusions can be effectively adsorbed when the alumina content is in the range of 20%-25%. In addition, the silicon content of Example 2 is 7.9%, which is 16% shorter than the spreading time of Example 1 (4.95%), indicating that the reduction and deoxidation effect is more significant when the silicon content is in the range of 5%-8%.

[0029] Comprehensive effect verification: When the fluorine content is within the composite ratio range of 30%-35%, calcium fluoride 20%-25%, aluminum oxide 20%-25%, and silicon 5%-8%, the material can simultaneously achieve: a melting point of ≤1300°C, which is 45-65°C lower than traditional auxiliary materials; a molten steel spreading time of ≤20 seconds, with fluidity improved by 40%-60%; an oxide inclusion area ratio of ≤0.03%, with a purification effect improved by 35%-55%. In particular, when the fluorine content exceeds 35%, although the melting point is further reduced, the aluminum oxide content increases to 29.8% accordingly, and the usage needs to be controlled within 0.12% to avoid the risk of carbon increase. Each example verifies that the present invention has achieved significant technological progress in metallurgical reaction kinetics, thermodynamics, and purification effects through the synergistic effect of specific components.

[0030] A method for producing a metallurgical material, based on the above metallurgical material, please refer to Figure 1 , including the following steps: Step 1: Classification and measurement of raw materials: Cryolite powder, fluorite powder and silica powder are stored in separate silos equipped with vibrating feeders. They are accurately weighed proportionally using electronic scales with an allowable error range of ±0.5%. The weighing data is transmitted to the central control system in real time. Step 2: Stir and mix: The measured raw materials are put into a twin-shaft mixer. The inner wall of the mixer is lined with wear-resistant ceramic linings and the mixing blades are spirally arranged. Pre-mixing is first performed at a speed of 30 rpm for 5 minutes, and then the speed is increased to 80 rpm for 10 minutes. The coefficient of variation of mixing uniformity CV is ≤3%; Step 3: Loading: The mixed material is transported to the pelletizing machine hopper through a bucket elevator. During the feeding process, a vibrating screening device is used to remove agglomerates with a particle size greater than 2mm. The screening efficiency is ≥95%; Step 4: Ball forming: The double-roller ball press is used. The roller skin is made of high-chromium cast iron with a surface hardness of HRC ≥ 58. The ratio of cavity depth to diameter is 1:1.2. The pressing pressure is divided into two stages: the first stage is pressurized to 10MPa and held for 3 seconds, and the second stage is pressurized to 18MPa and held for 5 seconds. After molding, the material is air-cooled to room temperature. Step 5: Particle size screening: Use multi-layer vibrating screens to grade and screen the molding materials. The aperture of the upper screen is 10mm, and the aperture of the lower screen is 5mm. The products with intermediate particle size enter the finished product bin, and the materials on the screen are returned to the mixing process for reprocessing. Step 6: Finished product inspection: The sieved materials are sampled and tested. The test items include fluorine content, particle size distribution and compressive strength. Qualified products are packed in ton bags with a net weight of 1 ton per bag. The top of the bag is equipped with a feed port and exhaust valve, and the bottom is equipped with a discharge port. A closed-loop control system uses sensors to provide real-time feedback on weighing data, automatically adjusting the feeding rate to maintain proportional accuracy. During the mixing step, a temperature control system is used to control the material temperature at 40-60°C. During the pelletizing step, pressure sensors and displacement sensors are used to monitor pressure and displacement changes in real time. During the particle size screening step, a dust removal device is used to effectively collect dust generated during the screening process. During the finished product inspection step, the material's fluidity and reactivity properties are tested. This method for producing metallurgical materials ensures product quality and production efficiency through a series of refined process steps. First, precise raw material metering and closed-loop control systems ensure the accuracy of raw material proportions, laying a good foundation for subsequent processes. Second, temperature control and uniformity control in the stirring and mixing steps make the mixed materials more uniform and stable, improving product performance. The vibration screening device in the feeding process effectively removes large-particle agglomerates, avoiding equipment blockage and product quality problems. The two-stage pressing and sensor monitoring in the ball forming step ensure the density and strength of the molded material, meeting the requirements of the metallurgical process. The multi-layer vibrating screen and dust removal device in the particle size screening step improve the uniformity of the product's particle size distribution and the cleanliness of the production environment. Finally, multiple performance tests in the finished product inspection step ensure the comprehensive qualification of product quality and provide reliable material guarantee for the metallurgical process.

[0031] See also Figure 1 The raw material measurement in step 1 adopts a closed-loop control system, which uses sensors to feedback weighing data in real time and automatically adjust the feeding speed to maintain the ratio accuracy, ensuring the accuracy of the raw material ratio; The closed-loop control system uses a weighing sensor to measure the weight of raw materials in real time. The data is transmitted to the central control system for comparison with the preset ratio. After calculating the deviation, the central control system uses a PID control algorithm to adjust the motor speed or vibration frequency of the vibrating feeder, thereby automatically adjusting the feeding speed. When the actual feeding amount deviates from the target value, the system can respond quickly and increase or decrease the feeding speed, forming a feedback loop. At the same time, an optional position sensor monitors the height of the raw materials in the silo to assist in judging the feeding progress. The central control system can also control the opening and closing of the silo valve to achieve precise control of feeding. In addition, the central control system interface provides real-time data display and historical data query functions, supports remote monitoring and operation, and ensures the accuracy of the raw material ratio. It significantly improves the accuracy of raw material ratio. Through real-time feedback of weighing data from sensors, the system can automatically adjust the feeding speed to ensure that the raw materials are accurately proportioned according to the preset ratio, avoiding errors that may be caused by manual operation. The closed-loop control system enhances the stability and reliability of the production process. The system can continuously monitor the weight of raw materials and automatically adjust according to actual conditions, effectively preventing problems such as excessive or insufficient raw materials and ensuring the stability of product quality. The system also improves production efficiency. The function of automatically adjusting the feeding speed reduces the need for manual intervention and the labor intensity of operators, while speeding up the production pace and improving overall production efficiency. The closed-loop control system also has the advantages of convenient operation and monitoring. The central control system interface provides rich real-time data and historical data query functions. Operators can easily monitor the production process and adjust production parameters in a timely manner to ensure smooth production. At the same time, the support of remote monitoring functions also improves the flexibility and maintainability of the system.

[0032] See also Figure 1 The mixer in step 2 is equipped with a temperature control system, and the material temperature is controlled at 40-60°C during the mixing process to prevent the material from overheating or agglomeration; The mixer should be designed to hold 50-200 liters of material to meet the needs of production of different scales. The speed adjustment range of the agitator shaft should be specifically adjusted to 50-300 rpm to meet the mixing requirements of different materials. In addition, the thickness and material selection criteria of the wear-resistant ceramic lining have also been clarified. That is, an alumina ceramic lining with a thickness of 5-10 mm is selected because of its high wear resistance, corrosion resistance and good thermal stability, which can ensure the long-term stable operation of the mixer. From the perspective of material formula, by accurately proportioning key ingredients such as fluorine, calcium fluoride, aluminum oxide and silicon, this material can effectively shorten the metallurgical cycle, improve metallurgical efficiency and reduce production costs. In terms of production methods, a closed-loop control system is used to accurately measure raw materials, ensuring the accuracy of the raw material ratio, providing a strong guarantee for product quality. The temperature control system equipped during the stirring process can monitor and adjust the material temperature in real time to prevent the material from overheating or agglomeration, ensuring the uniformity and stability of the mixture. The staged pressurization technology is used in the ball forming stage to ensure the stability and consistency of the forming quality. The dust removal device equipped in the screening process effectively improves the working environment and reduces dust pollution. The strict finished product inspection process ensures the reliability of material quality and meets the high standards of metallurgical technology.

[0033] See also Figure 1 The ball press in step 4 is equipped with a pressure sensor and a displacement sensor to monitor the pressure and displacement changes during the pressing process in real time to ensure stable molding quality; High-precision pressure sensor arrays are symmetrically installed in key pressing areas of the ball press, such as on both sides of the roller contact surface. Each sensor has a measuring range of 0-50MPa and an accuracy of ±0.1%FS. Laser displacement sensors are installed at both ends of the roller axis, with a measurement range of 0-20mm displacement and a resolution of 0.1μm. Sensor data is transmitted to the PLC control system in real time via industrial Ethernet. The system has a built-in PID algorithm that can automatically adjust the hydraulic system pressure and roller speed according to the real-time pressure-displacement curve to ensure dynamic matching of the pressing force and the material deformation. By real-time monitoring of pressure and displacement changes during the pressing process, the stability of the molding quality can be ensured. The sensor can accurately capture subtle changes in the pressing process and provide timely feedback data, enabling operators to quickly adjust process parameters to avoid product defects such as cracks and uneven density. Secondly, this real-time monitoring and feedback mechanism helps to achieve intelligent control and improve production efficiency. The combination of sensor data and PLC control system enables the ball press to automatically adjust key parameters such as pressing force and roller speed according to real-time data to maintain the best working state, reduce manual intervention, and reduce operating difficulty. In addition, sensor data also provides strong support for process optimization. By analyzing a large amount of production data, the bottlenecks and optimization points in the pressing process can be found, the process can be further improved, and product quality and production efficiency can be improved. Finally, equipping with pressure sensors and displacement sensors can also help improve the safety and reliability of the equipment. The sensor can monitor the operating status of the equipment in real time and detect abnormal conditions in time, such as overload and offset, to avoid equipment damage and safety accidents.

[0034] See also Figure 1 ,The vibrating screen in step five is equipped with a dust removal device to effectively collect the dust generated during the screening process and improve the working environment; The vibrating screen's dust removal device uses a bag-type dust collector. Its filter bags are made of high-temperature and corrosion-resistant synthetic fibers. The dust generated during the screening process is sucked into a sealed dust removal chamber through the principle of negative pressure suction. The dust-laden gas is evenly distributed by the guide plate and then passes through the filter bag. The dust is intercepted on the surface of the filter bag, and the purified gas is discharged from the exhaust port. A pulse jet cleaning system is also provided. The compressed air periodically vibrates the outer surface of the filter bag to prevent dust from caking. The collected dust is then returned to the production system via a screw conveyor for recycling. This device can improve the dust collection efficiency, significantly reduce the concentration of particulate matter emissions, fully meet the requirements of the metallurgical industry pollutant emission standards, and avoid the risk of environmental penalties due to excessive dust. Secondly, in terms of occupational health, the closed dust collection design makes the dust concentration in the working area ≤2mg / m³, which is far lower than the national occupational exposure limit for harmful factors in the workplace (8mg / m³), effectively preventing the occurrence of occupational diseases such as silicosis. Furthermore, in terms of equipment operation reliability, the pulse cleaning system can automatically monitor the pressure difference changes. When the filter bag resistance reaches 1200Pa, the cleaning program is started to ensure the continuous and stable operation of the dust removal system, avoiding equipment shutdown failures due to dust accumulation. From the perspective of resource recycling, the recovered dust particle size distribution (0.075-0.5mm) is completely consistent with the raw material ratio requirements. , re-blending can reduce raw material consumption. In addition, the closed dust removal design also brings additional safety benefits: eliminating the dust explosion hazardous environment (the original screening area belongs to Zone 21 explosion hazardous place), and the dust removal host with ATEX explosion-proof certification makes the workplace safety level raised to the non-hazardous area standard. Finally, the device is deeply integrated with the production line control system to monitor key parameters such as the temperature difference between the inlet and outlet of the dust collector and the operating current of the fan in real time, and upload the data to the central control room through the OPC protocol to achieve remote monitoring and fault warning, reduce equipment maintenance costs, and improve overall production efficiency. This technical solution not only embodies the unity of environmental protection and economic benefits, but also builds a technical barrier for clean production through systematic design, and provides a replicable solution for green manufacturing in the field of metallurgical material preparation.

[0035] See also Figure 1 ,The finished product inspection in step six also includes testing the material’s fluidity and reactivity properties to ensure that the material meets the metallurgical process requirements; During the raw material classification and measurement process, electronic scales are used for precise measurement, and the accuracy of the electronic scales is not less than 0.1kg to ensure that even small proportions of raw materials can be accurately measured, thereby improving transparency; It ensures that metallurgical materials not only meet the basic composition and particle size requirements, but also show excellent performance in the actual metallurgical process. Good fluidity enables the material to be evenly dispersed in the molten steel, avoiding local concentrations that are too high or too low, thereby significantly improving metallurgical efficiency. At the same time, suitable reactivity ensures that the material can fully react with impurities in the molten steel, effectively reducing the total oxygen content in the steel and improving the cleanliness of the molten steel. This is of vital importance for smelting high-grade steel grades, such as bridge steel, acid-resistant pipeline steel and container steel, because these steel grades have extremely strict requirements on material performance. Any tiny impurities or performance fluctuations may affect the quality of the final product. Through strict finished product inspection, it can be ensured that each batch of materials can meet the requirements of the metallurgical process, providing a strong guarantee for the production of high-quality, high-performance steel.

[0036] During the lifting process of the bucket elevator in step 3, the material is protected by inert gas to prevent oxidation reaction of the material during the lifting process. The inert gas flow is automatically adjusted according to the lifting speed and material amount to ensure that the oxidation degree of the material during the lifting process is less than 0.1%.

[0037] The surface of the roller skin of the roller ball press in the step 4 is provided with a fine texture structure, the depth of the texture structure is 0.1mm-0.3mm, the width is 0.05mm-0.15mm, and the texture is distributed in a cross-net pattern. This design can increase the friction between the material and the roller skin, making the surface of the formed pellets denser and the compressive strength increased by 10%-15%, while reducing the phenomenon of material sticking to the roller during the pressing process.

[0038] In step one, a high-precision electronic scale (such as Mettler-Toledo) is used to ensure an error range of ±0.5% to accurately control the raw material ratio; in step two, a double-shaft horizontal mixer (such as Edman) is used, lined with wear-resistant ceramics to improve mixing efficiency and uniformity; in step four, an HPY series double-roller ball press (such as Hongtao Machinery) is used, equipped with high-chromium cast iron rollers to ensure the quality of ball pressing; in the closed-loop control system, a PLC control system is introduced to automatically adjust the feed amount through real-time feedback from sensors; for temperature control, electric heating rods and temperature controllers are used to accurately control the stirring temperature at 40-60°C; Omron brand sensors are used for pressure and displacement monitoring to ensure precise control of molding pressure and displacement; finally, in the fluidity and reactivity tests, a Hall effect flowmeter is used to measure fluidity, and a thermogravimetric analysis is used to measure reactivity to comprehensively evaluate material properties; The precise ratio of fluorine, calcium fluoride, alumina and silicon enables the material to play an efficient role in metallurgical reactions, significantly reducing the total oxygen content in molten steel, improving the cleanliness of molten steel, and thus improving the quality of the final steel. Secondly, the usage of this material is only 0.1-0.15% of the mass of molten steel. This ratio not only ensures the metallurgical effect, but also effectively controls the cost and improves the economy of the metallurgical process. In addition, the production method of the material is scientific and rigorous. Through the application of closed-loop control systems, temperature control systems and high-precision sensors, the accuracy of the raw material ratio and the stability of the molding quality are ensured, further improving the reliability and consistency of the product. At the same time, the material is easy to transport and store. It is transported in ton bags lined with polyethylene film, which effectively prevents moisture and dust and adapts to various environmental conditions. In summary, this metallurgical material not only improves metallurgical efficiency and quality, but also reduces production costs, enhances the market competitiveness of products, and brings significant economic and social benefits to the metallurgical industry.

[0039] The material is suitable for the smelting of high-grade steel grades such as bridge steel, acid-resistant pipeline steel and container steel. It can reduce the total oxygen content in the steel and improve the cleanliness of the molten steel. This metallurgical material achieves remarkable metallurgical effects through the scientific proportioning of components such as fluorine, calcium fluoride, aluminum oxide, and silicon, combined with advanced manufacturing processes. Its precise component ratio and optimized manufacturing process ensure that the material can fully play its role in the metallurgical process, effectively reducing the total oxygen content in steel, effectively removing impurity elements in steel, and improving the cleanliness of molten steel, thereby significantly improving the mechanical properties and corrosion resistance of steel. This material is suitable for the smelting of various high-grade steel grades such as bridge steel, acid-resistant pipeline steel, and container steel, meeting the demand for high-quality steel in different fields. At the same time, the automated control system used in its production process, such as closed-loop metering, temperature control, and pressure monitoring, not only improves production efficiency but also ensures the stability and consistency of product quality. In addition, this material also has good environmental performance. The dust removal device equipped with the vibrating screen effectively collects dust generated during the screening process, improving the working environment. In summary, this metallurgical material, with its excellent performance, wide range of applications, and environmentally friendly production process, has brought significant economic and social benefits to the metallurgical industry.

[0040] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0041] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A metallurgical material, characterized in that: The material consists of the following components in weight percentage: composition: Fluorine: 25% to 40%; Calcium fluoride: 15% to 30%; Alumina: 15% to 20%; Silicon: 3% to 8%; The remainder is other oxides and trace impurities.

2. The metallurgical material according to claim 1, characterized in that: The amount of the metallurgical material used in the metallurgical process is 0.1-0.15% of the mass of the molten steel.

3. A method for producing a metallurgical material, based on a metallurgical material according to any one of claims 1 to 2, characterized in that: The steps include: Step 1: Classification and measurement of raw materials: The raw materials of fluorine, calcium fluoride, alumina and silicon are stored in separate silos equipped with vibrating feeders. They are accurately weighed proportionally using electronic scales with an allowable error range of ±0.5%. The weighing data is transmitted to the central control system in real time. Step 2: Stir and mix: The measured raw materials are put into a twin-shaft mixer. The inner wall of the mixer is lined with wear-resistant ceramic linings and the mixing blades are spirally arranged. Pre-mixing is first performed at a speed of 30 rpm for 5 minutes, and then the speed is increased to 80 rpm for 10 minutes. The coefficient of variation of mixing uniformity CV is ≤3%; Step 3: Loading: The mixed material is transported to the pelletizing machine hopper through a bucket elevator. During the feeding process, a vibrating screening device is used to remove agglomerates with a particle size greater than 2mm. The screening efficiency is ≥95%; Step 4: Ball forming: The double-roller ball press is used. The roller skin is made of high-chromium cast iron with a surface hardness of HRC ≥ 58. The ratio of cavity depth to diameter is 1:1.

2. The pressing pressure is divided into two stages: the first stage is pressurized to 10MPa and held for 3 seconds, and the second stage is pressurized to 18MPa and held for 5 seconds. After molding, the material is air-cooled to room temperature. Step 5: Particle size screening: Use multi-layer vibrating screens to grade and screen the molding materials. The aperture of the upper screen is 10mm, and the aperture of the lower screen is 5mm. The products with intermediate particle size enter the finished product bin, and the materials on the screen are returned to the mixing process for reprocessing. Step 6: Finished product inspection: The screened materials are sampled and tested. The test items include fluorine content, particle size distribution and compressive strength. Qualified products are packed in ton bags.

4. The method for producing a metallurgical material according to claim 3, characterized in that: The raw material metering in step 1 adopts a closed-loop control system, which uses sensors to feed back weighing data in real time and automatically adjust the feeding speed to maintain proportional accuracy.

5. The method for producing a metallurgical material according to claim 3, characterized in that: The mixer in step 2 is equipped with a temperature control system, and the material temperature is controlled at 40-60°C during the mixing process.

6. The method for producing a metallurgical material according to claim 3, characterized in that: The ball press in step 4 is equipped with a pressure sensor and a displacement sensor to monitor the pressure and displacement changes during the pressing process in real time.

7. The method for producing a metallurgical material according to claim 3, characterized in that: The vibrating screen in step five is equipped with a dust removal device.

8. The method for producing a metallurgical material according to claim 3, characterized in that: The finished product inspection in step six also includes testing the fluidity and reactivity of the material.

9. The method for producing a metallurgical material according to claim 3, characterized in that: During the lifting process of the bucket elevator in step three, the material is protected by inert gas, and the flow rate of the inert gas is automatically adjusted according to the lifting speed and the amount of material.

10. The method for producing a metallurgical material according to claim 3, characterized in that: The surface of the roller skin of the roller ball press in the step 4 is provided with a fine texture structure.

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