PRODUCTS OF “SOYUZ” GROUP
The “Soyuz” group produces and sells the specified materials in accordance with the regulations and technical documentation of Ukraine or at the request of consumers.
Deoxidizer, Modifier (inoculant), Carburizer, Carburizing agent, Slag Coagulant, Heat-insulating and Exothermic inserts and mixes (powder) for hot tops,
Non-stick additive in mix, Degassing, Refining
The products of “Soyuz” are mixed, powdered and as a rule packaged materials, they don’t require any preliminary preparation (crushing, sieving, weighing, etc.). The customer get materials in a completely ready to use form, the mass of the bag is set by the customer. Developments of “Soyuz” are protected by patents of Russia and Ukraine and have been using at enterprises of Ukraine, Russia, Belarus, Moldova, Kazakhstan, Uzbekistan, Bulgaria, Czech Republic, Germany, South Africa for about 20 years.
The first patent for a graphitizing modifier for cast iron MK-21g was received by the employees of the enterprise about twenty years ago. It was the first of a series of MK-packaged mixtures consisting mainly of powders of activated by high-temperature treatment carbon and physicochemical produced metallic silicon. In addition, the modifiers in the microdoses contained calcium, copper, aluminum and titanium. The main feature of MK is that some of them are in a highly dispersed state. This degree of dispersion and the special properties acquired by the substance during the transition to the ultrathin state, cause a sharp increase in the modifying ability and persistence of the mixture. This is despite the fact that they are three to four times cheaper than traditional graphitizers and, of course, user-friendly.
It was already noted that the mixed modifiers are experiencing a second birth now. Until recently, the production of mixture modifiers was mainly based on the use of recycled products (sometimes wastes) of ferroalloy plants. In new generation of mixed modifiers modern materials are used. These are modifiers based on ultrafine powders, the properties of which have not been fully discovered yet and are being studied now with increasing activity. It is clear that in fused modifiers the effects, that nano-materials can produce, are absent. Therefore the mixtures became the object of scientific research and the aria where specialists of the “Soyuz” found their technical solutions. Moreover it is important that they considered the mixture as a category of materials that allow merging individual components into a system that is not only multifunctional, but, ideally, synergistic, meaning increase in the efficiency of activities as a result of integration, the merger of individual parts into a single system. Such systems (mixtures) are tended to create in the “Soyuz” with significantly exceeding of technological properties in comparison to the sum of the properties of components.
The next, MK-21pc was patented – a highly effective diffusion deoxidizer for steel. Dozens of Ukrainian plants currently use this deoxidizer, such as the largest advanced enterprises, primarily producing products for the Ministry of Railways: Kremenchug Steel Plant, Dnepropetrovsk and Kerch railway Switch plants, Dneprodzerzhinsk Steel Mill, enterprises of the Donetsk and Krivoy Rog Basins – “Energomashspetsstal”, closed joint stock company Krivoy Rog plant of the mountain equipment, Foundry and Mechanical plant, “REGOM”, “KrivorozhGormash” and “KrivorozhRudmash”, as well as machine-building and specialized companies of JSC “Dniprotyazhmash”, Starokramatorsk Machine-Building Plant, “Electrotyazhmash”, Plant named after Malyshev (Kharkov) and even more than 20 foundry and machine-building plants in Ukraine.
This project turned out to be so successful, and the demand is so great that a symmetrical enterprise for the production of MK materials (and a deoxidizer in particular) was made in Russia. Today, it supplies high-tech products to foundries in Russia and Kazakhstan. And since 2008 supply deoxidizer to Belarus have started.
Another consequence and proof of the high demand for MK is the appearance of either counterfeit products, or surrogates with similar names and made with uncertain technology (usually use waste of abrasive production). The negative consequences of the use of such materials sometimes (unfortunately) do not affect immediately.
Another feature of the “Soyuz” is that its materials – technological mixtures – are almost always delivered in bags of a concrete, coordinated with the customer and convenient for him mass. Bags are convenient not only for transportation and internally displacements, but also from a functional, technological point of view. For example, if it is a graphitizing modifier, the mass of the bag is calculated for the weight of the metal in the ladle of a particular customer. For non-stick additive MK10l the mass of the bag is calculated for the mixture formula in runners (if they are periodic). Fluxes and other are also packaged. Even when the “Soyuz” did the fused alloys (for example, FSMg) those for individual enterprises were supplied in bags designed for the ladles of the customer.
Modifiers, carburizers, deoxidizers (MK)
Packaged graphitizing modifier MK-21g for cast iron.
It’s intended for out-of-furnace graphitizing treatment of cast iron. Foreign analogues are “Kaloy”, “Nukaloy”, etc. It contains activated carbon and silicon, and, in small amount, copper, aluminum, calcium, titanium. Part of the components is in the ultrafine state. The mass of the bag is calculated for the mass of the metal in the ladle (1bag / 1ladle). Its consumption is low. It’s good remover of chill and keeps the modifying effect long time (has increased persistence).
Modifiers promote the appearance of a large number of crystallization centers of graphite in the melt, and this quantity remains in high level during melt for a long time, while retaining the modifying effect (increased workability). It reduces the number of defects of nonmetallic inclusions, gas pores and shells, as well as shrinkage.
It’s suitable for treatment of cast iron smelted in all types of casting furnaces, and also compatible with other stages of cast iron treatment (alloying, balling-up, refining, etc.).
The technology of application allows any of the known methods of its addition to the melt, including automatic.
Packaged deoxidizer for steel MK-21pc.
MK-21pc is designed for diffusion deoxidization of steels and slags of arc furnaces, ladle furnaces, as well as at tapping from the smelting unit before the addition of basic ferroalloys instead of traditional deoxidizing mixtures, ground ferroalloys, calcium carbides and silicon, and aluminum.
MK-21pc is applicable for any enterprise that has in its arsenal arc furnaces, both with a basic and acid lining, as well as enterprises, where the problem of slag control and the inevitable entry of highly oxidized slag into the ladle at tapping is acute, for example – converter shops, which requires measures to reduce its oxidizing ability for further treatment at the out-of-furnace finishing plants and, accordingly, lead to overspending of expensive deoxidizing materials. MK-21pc has an increased affinity for oxygen; it reduces the ferroalloy and deoxidizer waste at steelmaking, increases the desulphurization and reactivity of the slag, and increases the purity of steel in gases and non-metallic inclusions.
The mixture is packaged in bags of precisely defined (agreed with the customer) mass, which allows to economically and evenly use the material and prevent the components of the mixture from drifting, as well as to increase the economics of the process.
The nomenclature of melted steels – from simple carbonaceous to low-carbon complex alloyed, stainless, heat-resistant, special steels.
MK 21 pc is used in many enterprises, differing in technological processes and methods, the range of products, as well as the capabilities of the equipment and the materials used.
Successfully used by enterprises of Ukraine, Belarus, Russia, Kazakhstan, South Africa.
Packaged carburetors MK-91 for graphitic iron, ductile iron and steel.
It’s applied to adjust the composition of iron and steel for the content of carbon melted in the foundry and steelmaking industries, for carburization of synthetic iron in the process of finishing the steel in the ladle furnaces.
It provides high assimilation of carbon. Has different grades by fraction, carbon, sulfur. Carbon content is from 96 to 99.5%, sulfur is 0.05-0.5%.
1.4 Non-stick additive “Kontrasand” (MK-10l) for sand-clay molding mixtures (analogous to the imported “KARBOLUKSON”, “ANTRAPUR”, “NAYVOK”).
It causes rapid gasification under the action of heat of the poured metal into the mold and makes a reducing atmosphere in the cavity; has high yield of brilliant (pyrolytic) carbon from the gas phase that formed during the pouring process; decreases of thermal stresses that arising in the surface layers of the form. In addition, it helps to reduce the level of production defects such as expansion scabs. It contains up to 40% of volatile, the yield of “brilliant” or pyrolytic carbon is 8-12%. It has minimal content of impurities (sulfur, nitrogen, etc.). And causes minimal formation of pyrolysis products (benzene, polycyclic aromatic hydrocarbons, carbon monoxide). Consumption – up to 2% of the weight of the molding mixture.
1.5 Packaged silicon pseudo-alloy MK 01 – for increasing and regulating the silicon content in the melt.
2. Complex mixtures (SK)
2.1 Slag coagulator (SK-1) is for fixing and making easier deslagging process in melting furnaces and ladles (foreign analogues “REMMOS”, “SLAX”, “BARIER”). It can be used in every enterprise that smelting iron and steel in induction furnaces with tipping ladle, torpedo ladle, lip-pour ladle (without a partition) in its technological process. It fixes and removes the slag from the metal screen. Increases the absorption of modifiers and alloys, prevents the rapid cooling of the melt.
SK-1 allows to reduce the waste of slag inclusions and to increase the resistance of the lining. Reduces the laboriousness of cleaning the metal from slag and eliminates metal losses during cleaning.
Slag coagulator does not affect the physical and chemical properties of the metal and is applicable for all grades of iron and steel.
2.2 “Thermos” (SK-2) is a heat-insulating powder. It’s an inert material with a low heat-accumulating capacity and a low exothermic effect. Designed for reducing heat loss with convection and radiation from the surface of the metal of open hot tops; insulating of the head of the ingot while pouring steel into the molds; reducing of thermal losses of metal in bottom-tap ladle, slide-gate ladle and lip-pour ladle.
2.3 “Destructor” (SK-3) is a softener. It’s designed for facilitating the knocking out of molds and molding cores made from the liquid glass – reduces the time and cost of knocking out process. It’s ecological and effective. Doesn’t require special equipment or changes in technology (it is added during mixing).
2.4 “Termite-2” (SK-4) is an exothermic powder for the open hot tops of casts and head parts of ingots (analogous of Ferrux 707/5 manufactured by Foseco). Allows increasing the metal yield of cast steel and cast iron, reduces shrinkage defects.
2.5 Heat-insulating powder (SK-5) is designed for reducing heat losses with convection and radiation from the surface of the metal screen of open hot tops at nonferrous casting.
2.6 Heat-insulating mixture (SK-7) intended for formation of insulating inserts in open and closed hot tops in order to increase the metal yield and to improve the efficiency of filling of casts in the process of crystallization.
2.7 “Forsage” (SK-09) is a drying accelerator (drying catalyst) for molds and molding cores with a liquid-glass binder. The way of solidification is heat drying and CO2 process. Consumption is 0.15-1.5% of the mass of the bulk solids.
2.8 “Likvos” (SK-1p) is a slag flux (analogue of fluorspar). It is designed for fluxing of slag at smelting of carbonaceous, low alloyed and complex alloyed steels in arc furnaces with basic lining, provides high rate of metal desulphurization and improves the environmental work conditions.
3. “Terminator Ch”- flux for cleaning of the lining.
It’s designed for cleaning of the lining of induction furnaces and ladles during melting of iron and steel. Removes slag crusts, increases the time period between repair of the lining, improves the efficiency of furnace and ladle work due to maintaining the working volume and reducing the heat loss.
4. “Hardex” lacquer
It reinforces the surface of molds and molding cores TU U 24.3-34850022-001: 2007. It is designed for reducing the peeling off the molding and core mixture, prevent drop and expansion scab. It is used for all types of molding and core mixtures, including raw sand-clay mix.
5. Fluxes and degassing packages for non-ferrous alloys
5.1. “Shchit” (“shield”) is a cover-refining flux for aluminum casting. Its purpose is to remove gases from the melt, to remove nonmetallic inclusions, to minimize the metal amount in the slag, to reduce aluminum losses associated with oxidation during melting, to allow melting of recyclable chips of aluminum alloys.
Mechanism of action is cleaning the melt due to the adsorption-flotation processes in the flux-metal system; creation a protective layer on the melt surface, which prevents oxidation, gas saturation and interaction of liquid aluminum with furnace atmosphere gases; deoxidizing the slag.
The scope is producing a technical aluminum (grades AO- A85), alloys of the Al-Si system, Al-Si-Cu and Al-Si-Mg systems. Its consumption is 0.1-1.0%, depending on the fraction of charge materials.
5.2. “Shlem” (“helmet”) is a cover-refining flux for copper alloys. Has protective and refining functions. Its consumption is 0.2-0.5%, depending on the fraction of charge materials. Scope of application is producing a copper, a brass, aluminum and tin bronzes.
5.3. “Antimag” is a flux for the removal of magnesium and alkaline-earth metals from aluminum alloys, protects from oxidation and gas saturation, refining the melt from slag inclusions and gases.
5.4. Degassing and modifying packages for aluminum casting. Remove hydrogen and other gases from the melt, as well as nonmetallic and slag inclusions; significantly reduce porosity in accordance with GOST 1583-89; increase of 20-30% fluidity and mold filling; modify the eutectic and primary silicon, the grain of the α-solid solution of silicon in aluminum.
Mechanism of action is refining the melt due to chemical fixing of hydrogen which dissolved in the metal. The resulting slag is dry, well deslagging from the metal surface, metal losses are minimized.
Processed alloys: technical aluminum (grades AO – A85); alloys of the Al-Si system, Al-Si-Cu, Al-Si-Mg and Zn-Al-Cu systems, alloys of the ZAMAK system. It is added with the cap; The reaction time is 3-5 minutes. It has a low rate of consumption (up to 0.05% of the mass of the melt being treated).
6. Exothermal and isothermal inserts manufactured by “H.A. KOVOCHEM”
Exothermic inserts are designed for gate systems for the production of cast steel and cast iron. The purpose is to eliminate the casting defects caused with shrinkage defects, which is achieved due to local heating of the liquid metal (up to 1800 °C), slowing the melt solidification process in the hot top part of the gate system and creating additional gas pressure on the metal in the exothermic reaction zone. The catalog of insert is here.