Olivine Materials for Foundry Industry

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1 John A. Pulbrook Manager, Sales & Marketing Mobile: Olivine Materials for Foundry Industry 1. Olivine Sand & Coating Material Powder for EPC Rationale Target Product name MgO SiO2 TFe2O 3 Al2O3+ CaO LOI True Specific Weight (Bulk Density) Refractorines s EPC-M2S-7# powder EPC-M2S-4# powder (raw) EPC-M2S-4# powder (ripe) Operating Guide Product name Size, Color Application Technique and Feature Application: As water based Coating Material - Powder for EPC Features:(1) It was calcined under a high temperature about 1,550, LOI<0.7,MgO 48, refractability (2) Compared with the unshaped metal oxides such as zircon sand, brown sapphire, quartz powder, etc. This product has no phase transition from room temperature to the 1900 melting point, it T-M2S-2# Coating Skeletal 200 mesh, red has a stable hot property, good stability, Material Powder and no radiation or damage of free SiO2 anthracosis. (3) The coating has good density and ventilation property, the castings will not adhere to the sands in the applied range, it s effectiveness is better than zircon sand coating in the high and middle alloy steel such as stainless steel, high manganese steel, etc. Applied Range: It applies to the production of non-ferrous alloy and all of the alloys of steel/iron except carbon steel and low alloy steel, which is similar to carbon steel. Q-M2S-1# Q-M2S-2# 6~12 mesh, cyan 12~18 mesh, cyan Application: As conduction sand for EPC. Features:(1) It won t absorb water and crash into powder under high baking and sintering with molten steel/iron over and over, it s re-usability is 6~8 times more

2 Q-M2S-3# 18~30 mesh, cyan than quartz sand and monticellite. (2)There is no free SiO2 powder, so it can eliminate the damage of anthracosis from production and operation workers and the public on the route. (3) The grain shape is polygonal, with no sharp angles. The sand has good liquidity, and the bulk density is 1.8g/cm3, it will not collapse. Applied Range: As EPC dry sand it can produce all kinds of castings. 2. Olivine Sand & Coating Material Powder for Sand Pattern Casting Foundry Rationale Target Product MgO O2 Fe2O3 Al2O3+CaO LOI True Specific Weight (Bulk Density) Refractoriness ( ) T-M2S-1# Q-M2S-5# Q-M2S-6# Operating Guide Product Size, Color Application Technique and Feature name T-M2S-1# 320 mesh, red Application: As alcohol group coating material powder for sand pattern casting foundry. Features: (1) It was calcined under a high temperature,loi<0.7,mgo 48, refractoriness (2) Compared with the unshaped metal oxides such as zircon sand, brown sapphire, quartz powder, etc. This product has no phase transition from room temperature to the 1900 melting point, it has stable hot mechanical properties, good fragility, and no radiation or damage of free SiO2 anthracosis. (3) The coating has good density and ventilation property, the casting will not adhere to sands in the applied range, it s effectiveness is better than zircon sand coatings in the high and middle alloy steel such as stainless steel, high manganese steel, etc. Applied Range: It applies to all kind of sands, core coatings, such as resin and water-based quartz sands, M2S sands, etc is used to produce all of the alloyed castings except carbon steel, low alloy steel which are similar to carbon steel and grey cast-iron. Q-M2S-5# 40~70 mesh, mignonette Application: As water-based sand and resin sand etc. for sand pattern castings and all kinds of casting. Applied Technique: 1. Yichang pure olivine sand will not absorb water or crush easily while it s baked by the molten steel and is used over and over. It s Moh hardness is 7.0, so it s reusability is good. It has no phase transition while heating, so the mould core has good resistance to sand inclusions. Both new and old sand have no free SiO2 powder, this puts an end to the damage of anthracosis, it s an excellent quality, environmental casting sand. 2. All kinds of alloy steel and castings except carbon steel and low alloy steel can be produced if we add some M2S-8 # alcohol group paint to the

3 core. And all kinds of carbon steel and low alloy casting can be produced if we add some alcohol based zircon sand paint to the core. This technique and material combined with equipment for dry method and to re-use the old sand, can make M2S old sand reusable and lifelong as single sand. Old sand is better than new sand, this can improve the castings apparent mass level and reduce the cost of moulding material, and also can reduce pollution. Q-M2S-6# 50~10 mesh, mignonette Application: As casting sand - resin sand, waterbased technique and wet mould exterior, etc. Applied Technique: (1) Same as M2S-5#. (2) For water-based process, Q-M 2 S-6# can produce less than 10 tonnes/piece of high & medium alloy castings, a mould core with no painting and it s smooth surface will not stick, it has good quality and casting precision. Applied Range: It is only applied to stainless steel, high manganese steel and other medium alloy steels. 3. Olivine Sand for Water Glass Casting Sand pattern casting is the most popular method of iron and steel castings, its production occupies about 80~90 of the whole foundry casting industry. According to statistics, to produce 1 tonne of castings we need 1~ 1.7 tons new sand and it will waste large amounts of old sand. China produces 1,200,000 tonnes castings per year now, and the discharge of old sand is about 1,200,000 tonnes per year. This not only occupies a large amount of land and waste but also a large amount of natural resources. So it does improve the Foundries manufacturing cost and also makes the environment more polluted. Sand casting includes three types of sand mixtures, 1. clay sand mixture, 2. resin sand mixture, 3. water-based sand mixture. Compared with clay sand mixture, which produces dust pollution and black pollution, resin sand mixture which will produce chemical pollution and the water-based sand mixture, which belongs to the inorganic binder system, is the very sand mixture technique, that is environmentally friendly. Sodium silicate sand is made up of Mg-olivine (or orthodox quartz sand, 70 sand) and an inorganic water glass binder. It adopts CO2 or organic resin as a hardening agent, the production environment is good and it doesn t produce any harmful gas emissions. There are (2) two difficult problems with the water-based process: the collapsability is bad and the reusability of old sand is difficult. But for Mg-olivine sand, it s collapsibility is better because it s alkalescency, has no phase transition, and it s collapsability is good (the collapsed point of Yichang M2S sand is 800, but the quartz sand s 200.) If we transferred it into organic resin, water glass, its collapsibility can be on par with resin quartz sand. To solve the problem of old eater-glass sands reusability is the necessity of competent department such as railway, shipbuilding, steel production, etc. and factories belong to them for years. Mass of deserted old water-glass sand not only increases transportation cost, waste s the limited resource, but also caused serious pollution, so realize the old sand s complete reusability is the aim of casting workers for years. Our country passed through Solid Waste Pollution Control Regulation in 1995, the State Council ratified National environmental 95 Plan and the Prospect Aim in 2010 in the same year, it improved a problem of how to control the discharge of pollution in the whole country and a plan of a trans-century environmental project, the reusability of waterglass sand is the request of Pollution Control Regulation. Our country did research for so many years to realize water-glass old sands dry reusability and wet reclamation is the most economical and ideal choice.

4 Yichang Mg-olivine sand s content of Al2O3+CaO is less than 0.8, the content of Al2O3+CaO is the lowest in the same kind of resource all over the world, so will not absorb water or crash easily while it s baked by the molting steel over and over. Its Mohs hardness is This is the biggest advantage compared with the sands in Henan Province and in Shangnan. According to the Olivine sand for EPC users statistics, we know that 1 ton Yichang Mg-olivine sands reusability is equivalent to 6-8 tons quartz sands and 10 tons monticellite sands. If water-glass sand can be recycled, it ll give play to pollution of Mg-olivine sand s right characteristic, reduce the company s cost, reduce the pollution of old sand s discharge, and avoid anthraces, it also makes possible for problems such as water-glass s collapsibility Size: M2S-4# mesh, for EPC M2S-5# 30-50mesh, for Water Glass Casting M2S-6# mesh, for Water Glass Casting M2S-7# mesh, for Water Glass Casting M2S-8# mesh, for V-technique casting The grain is polygonal, its True Specific Weight is 3.14g/cm³, Mohs hardness is , MgO 45, Al2O3+CaO<0.8, refractoribility (Ripe sand: MgO 48, LOI<0.7, refractoriness 1750 ) 4. Covering Flux For melting steel Chemical composition Component SiO2 Al2O3 Fe2O3 MgO CaO Na2O K2O C Content Physic property mark Grain size (mesh) Bulk density LOI Water capacity Melting point( ) (g/cm³) For melting iron Chemical composition Component SiO2 Al2O3 Fe2O3 MgO CaO Na2O K2O C Content Physic property mark Grain size (mesh) Bulk density LOI Water capacity Melting point( ) (g/cm³) Kebo 1# Caking Agent Kebo 1# caking agent is an ideal caking material which is poisonless, tasteless and environmental. It is a kind of powdery caking agent which has strong cohesive property, high baked strength, good liquidity and collapsibility which is applied to making up the first and second class complex and high strength core plan. It can replace the orthodox tang oil and Rick fat oil completely to be core binding material. It can be used in steel casting, iron casting, non-ferrous casting, automobile, machine tool, diesel engine, water pump, textile machinery, etc. Main features: 1. It has no strict demand on roughing sand s shape, grain, moisture content, sediment percentage, etc. The wet roughing sand whose moisture content is 70 can be used directly, its capable of adopting is good, its old sand has no inert film, and we can reuse it directly. 2. There is no need to add other ancillary materials but only add proper water in it that we can get the right degree of dryness and humidity if we use this kind of caking agent to make up sand core. 3. This product can be used every two days and the sand core will not creep deformate easily. 4. The speed of vapor produce is low, the time of it is short, and these eliminate the castings pore defect which was leaded by the vapor produce of loam core efficiently. 5. It is easy to ram off because its collapsibility is very good. 6. It has great economic benefit for the cheap price, little addition, short time to bake the sand plan, and save energy and electricity.

5 7. Its liquidity is worse than tang oil and rick fat oil. If the moisture property is too high or too low, it will affect the degree of dryness and humidity, and this may cause mold sticking, but we can solve it by adding 0.5 tang oil, bean oil, rape oil etc. Use method: 1. Making up technique: 100 raw sand+ caking agent 2-3+ water 6-9 (user can find out the proper moisture content according to the applied raw sand. 2. Mixture technique: mix raw sand+ caking agent dry (about 2-3 minutes), and then mix them wet (about 8 minutes). 3. Bake technique: the baking humidity depends on the core plan s size and thickness. Usually is ok. Attention: 1. We must measure the raw sand s moisture content correctly if use wet sand directly. We need adding water into it when the moisture is low, or it will affect the dry tensile strength. 2. We can add 1-3 clay if the sand core s demand of moisture is high. 6. Fusible Pattern Precision Casting Technique and the Reference Material Fusible pattern casting (instructive molding process) is a more advanced casting process at home and abroad currently. Its process is easy, intensity of labor is little, and the environment is good, so it becomes the first choice of many casting companies. This means that our casting process is changing into a new type. In order to adjust to this new process, our company exploits M2S (Mgolivine) sand and powder which applies to the low and high alloy steel and non ferrous metal investment casting. Fusible pattern casting s die set is paraffin. First, adhering all kinds of high refractory sand and powder to the surface of the die set layer by layer by a special caking agent (eg. Water glass etc.), the procedure is: mesh 2# powder mesh 8# sand mesh 6# sand mesh 4# sand, we should use the sand according to the clients demand to achieve the pouring temperature of molten steel (iron) and get good ventilation property. Then, drying the molds, and later put them into hot water (about 100), let the paraffin soften and blend into the water and leave a empty die space. Last, drying the die space and put it in the backing sand after drying, waiting for pouring. Steps: Moulding: The first layer is coating layer (M2S coating material 320 mesh) Put the wax pattern into the paint pool to make it get a coating, and then soak it in the ammonia pool. The second layer is back-up coat1 ( mesh calcined or mesh calcined M2S sand) Get the wax pattern from ammonia pool to the boiling sand hopper to adhere mesh sand even. The third layer is back-up coat 2 (M2S 6# sand) Get the second sand layer to the pattern. By analogy, there is no need to use M2S sand from the third back-up coat, we can use some larger grain size sand optionally, the layer should be 7, at least 6. Mould stripping: Put the wax pattern into oven or hot water (both ) to dewax, get out the wooden block, and put the mold into oven to parch it. Pouring: Bury the parched die space in the workshop sandlot to tight it, wait for pouring. The choice between sand and powder: high refractory, even grain, low dust content ( 0.3), low LOI.

6 Reference mesh: mesh M2S powder mesh M2S calcined sand mesh M2S (calcined) sand mesh M2S (calcined) sand Olivine Materials for Metallurgical Industry 1. Covering Agent for Ladle For melting steel Chemical composition Component SiO2 Al2O3 Fe2O3 MgO CaO Na2O K2O C Content For melting iron Chemical composition Component SiO2 Al2O3 Fe2O3 MgO CaO Na2O K2O C Content Used in the ladle, covering agent can preserve the heat, prevent the molten steel from oxidation, and absorb some occluded foreign substand floating upward in the molten steel to make the ladle liner be eroded less and be turned over easily, this can improve workers working condition. 2. Drainage Sand for Sliding Gate Rationale Target Main Component Cr2O3 SiO2 T Al2O3 MgO C H2O Temperature Size: mm mm Package: Outside:1 ton; Inside: 10kg. (We can change the package size if necessary.) Drainage sand s thermal stability and resistances to acid & alkaline molten steel/iron are good. Stuffing material (Conduction Sand) of Tap Hole (EBT Filler) MgO SiO2 CaO Al2O3 T Fe2O3 C Temperature Main Component Size: 2-5mm; Concentration ratio of grain: 95 Package: Outside:1 ton; Inside: 20kg. (We can change the package size if necessary.) It s made up of excellent M2S and magnesium sand by adding compound agglutinant, it has moderate sintering character, good liquidity, high free-opening rate and some other features. It applies to be stuffing material of EBT-filler. Being proved by several steelmakers, its quality is stable, it s cheap, it s free-opening rate can be 100, it s the first production to replace importing.

7 2. Chromites-based Drainage Sand for Ladle Its main raw material is high quality chromites sand which is imported from South Africa, it s made by processing with majorized formulation and advanced technique. Features: It can sinter quickly on the surface after touches the molten steel, this can keep molten steel from infiltrating. 2 Its high refractoriness makes a moderate sintered layer, its resistance of agglutinating property is good. 3 It used correct lubricant, the moisture is under 0.5 after a high temperature baking, and its liquidity is good. Products Technique Target: Item Cr2O3 MgO SiO2 Al2O3 TFe C H2O Refractoriness Target Package: Adopt double deck plastic with moisture resistant package outside. The size is 5kg/bag or 10kg/bag. (We can change the package size if necessary.) Attention: 1 No matter add it upright or parabolic, the conduct must fulfilled the brick cup, the appearance of it is embossed like steam bread, this can improve the conduction rate. 2 Keep the liner ladle water gap cleaning. 3 Keep the conduction sand dry. 3. Continuous Casting Ladle Heat Preservation Flux Features: In order to meet the demand of casting adequate and systematic service, combined with different steel and liner tympani, our company s FG system heat preservation flux can be divided into high carbon FG-GC, medium carbon FG-ZC, low carbon FG-WC according to the carbon content. This product has many features such as good spreadability, strong heatinsulating property, long heat preservation time, it can absorb enclosure, and it won t be incrust, will not damage the liner, will not pollute the molten steel, etc. so it s rated with the clients. Rationalize Target Products target FG-GC FG-ZC FG-DC FG-WC SiO2 33±5 42±4 42±5 CaO 5±3 4±2 4.5±2 Al2O3 15±5 23±2 33±5 MgO ±3 R2O - 7±1 - C ±1 <5 H2O > ±50 g/ml mm Unshaped Mg-olivine Skeletal Material Because magnesia in our country is becoming more and more rare, the market price is keeping up, this brings perplex of increasing the cost of magnesia refractory manufacturing companies which Mg-Olivine is valued as a kind of substitute material for magnesia sands day by day. Been proved by some refractory companies which have used this product, we know that if add Mg-olivine in the castable refractory, gunning mix, spread dry sand and other unshaped refractory to replace part of magnesia sand while steelmaking will not decline it s function, but can decrease the produce cost and increase its marketing competition.our Mg-olivine can meet all kind of demand of clients after it is crushed, its rationale target can be:

8 Main Component MgO SiO2 CaO Al2O3 T Fe2O3 LOI Refractability We have a tunnel kiln and two kilns, we can provide roasted Mg-olivine in all size, its rationalize target can be: Main MgO SiO2 CaO Al2O3 T Fe2O3 LOI Refractability Component Materials of Mg-olivine Mg-olivine Refractory It s a kind of refractory material which 2MgO SiO2 (abbr M2S) is the major component. The content of MgO is 35-55, MgO/mm SiO2 = 0.94~1.33 Except the chief crystalline phase M2S(65~75), it consists of MgO, magnesium ferrite and some other minerals (15). M2S crystal is big and becomes structure framework. The other minerals do not exist as combo, but exist in the cracks of Mg-olivine crystal as inclusion. So Mg-olivine s characteristic is depending on Mg-olivine. The melting point of pure Mg-olivine is 1890C. Mg-olivine is the only stable refractory phase in M2S. Mg-olivine has a very high refractoriness under load, the temperature of initial distortion of products which added magnetite can be 1650~1750C and even more high. M2S products have a strong ability of resistance melting FeO but the resistance of CaO is weak, and the resistance of clay and high-alumina is weaker. Its resistance of thermal shock is better than common magnesia brick, but its shortage is its porosity is high. Its QI s fluctuation is as following. Refractoriness 1830~ MPa refractoriness under load 1580~1620 temperature/ Crack temperature/ 1650~1710 Apparent porosity/ 26~28 Volume concentration/g cm³ 2.35~2.42 Compressive strength/mpa 2.0~3.0 Resistance of thermal shock/time 5~14 Fire shrinkage(1700 can preserve heat for 0.8~1.4 2h)/ M2S refractory material is applied to be M2S firebrick in metallurgy, M2S unshaped refractory, open-hearth s regeneration check brick, pouring brick, mill furnace bottom and it also has good effects when be used in copper smelter. Magnesia Material and Its Products Rationale Target Item MgO SiO2 TFe2O3 LOI M/S Refractability () Refractoriness under load() Hardness (grade) Magnesian material 62 Magnesian special ceramics >1790 >

9 Special ceramics products performance index comparative list Material class Corundum+ porzite White alumdum fused magnesite Magnesia products Products illustrate Heat-resistance Mandril - system Products Series of products pottery brick products Salinity Neutral Neutral Alkalescence Weak Alkalescence Refractoriness () >1770 >1770 >1770 >1790 Thermal shock stability(1320/wind cooling) Refractoriness under load() > Flexural strength(mpa) Volume concentration(g/cm3) Apparent porosity Applied range Automobile spark plug mill, Electronic industry Heat engineering mandril for high temperature equipment Blast furnace block, electronic furnace inside lining Special materials ceramics The use of product Magnesia can be used as di-electric ceramic, high voltage insulation, especially can be used for electric pile ----crunch seal. Magnesia ceramic is a new-type electro-technology material which is stable for a long time in 500KV direct current electric field. Meanwhile, the current intensity will not be reduced. The traditional electro-technical porcelain, glass, plastics cannot be satisfied. But the Magnesia ceramic is the best di-electric ceramic and manufactured vacuum tightness metallic combo which has the insulation, tarnish resistance, soundness, quality, stability and reliability. It s also used as special insulation in ceramics for space flight, electronic, chemical engineering, medical science, mechanical etc. Magnesia ceramic is widely used in electric heater which can be used instead of fused magnesite. Magnesia ceramics can be used instead of some electric corundum, electric cast mullite and carborundum because of its high load (0.2MPa), sintering temperature (1650 C, 1750 C) and heat shock stability. It s also used for new product in ceramics, especially for cars, electronic. Magnesia ceramics are widely used in metallurgy, foundry as the high temperature insulation and refractory consumption. Presented by: John Pulbrook (Distributor for Yichang Kebo Olivine China)