Calcium Metal – Pieces / Cored Wire
Calcium Metal (Ca) is an alkaline earth metal, which, in its pure metallic form, is an extremely powerful deoxidizer, desulfurizer, and inclusion modifier for molten steel and non-ferrous alloys. It is never added as pure pieces directly to open steel because of its high reactivity and low boiling point. Instead, it is supplied as small pieces for alloying or, most commonly, contained within a cored wire for precise, deep-bath injection during secondary steel refining.
Main Function and Reaction
Calcium is utilized for its exceptional chemical reactivity with oxygen, sulfur, and specific non-metallic inclusions.
| COMPONENT | CHEMICAL FORMULA | PROPERTY HIGHLIGHT |
| Calcium | Ca | Low boiling point (~1484°C), high chemical affinity for O and S. |
| Reaction Byproduct | CaO, CaS, CaS·Al2O3 | Stable, spherical, low-melting inclusions (liquefied at steel T). |
| CLASSIFICATION | DELIVERY METHOD | PRIMARY APPLICATION FOCUS |
| Purity Agent | Cored Wire Injection | Shape control of inclusions and ultra-low desulfurization. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Desulfurization Power | EXTREME | Highly effective at removing trace sulfur down to < 0.001%. |
| Inclusion Modification | CRITICAL | Converts brittle, high-melting alumina inclusions (Al2O3) into soft, spherical, low-melting Calcium-Aluminates (CaS·Al2O3). |
| Yield/Safety | LOW | Due to high volatility, pure Ca is impractical and dangerous unless contained (i.e., in cored wire). |
The Inclusion Modification Mechanism (Shape Control)
This is the most critical use of calcium in high-grade steel. When steel is deoxidized with aluminum (Al), sharp, solid, and stringer-like Al2O3 inclusions are formed. These inclusions are detrimental to the steel’s properties (e.g., they cause nozzle clogging during casting and reduce fatigue life).
The addition of calcium modifies these inclusions:
The resulting calcium aluminates are globular and remain liquid or soft at steel casting temperatures. This is vital because liquid inclusions:
- Prevent Nozzle Clogging: They flow smoothly through the submerged entry nozzle.
- Improve Mechanical Properties: They are less damaging to the material’s internal structure during rolling, greatly enhancing the steel’s ductility, formability, and isotropy (uniformity of properties in all directions).
Delivery Method: Cored Wire
Due to calcium’s low boiling point (~1484°C), which is below the temperature of molten steel (~1600°C), adding pure pieces causes immediate, explosive vaporization, leading to massive yield loss and safety hazards.
Cored Wire solves this:
- The Wire: A steel sheath (wire) is filled with calcium powder or alloy (like CaSi).
- Injection: The wire feeding machine drives the wire deep below the surface of the molten metal.7 The steel sheath protects the calcium until it reaches the zone of low ferrostatic pressure, where the calcium melts/vaporizes and is dissolved into the steel with high efficiency (25% to 50% yield).
Typical Industries and Applications
- High-Quality Steel: Production of bearing steel, line pipe steel (oil & gas), and automotive sheet steel, where strict inclusion control and low sulfur are mandatory.
- Non-Ferrous Alloys: Used as an alloying element in some high-strength aluminum alloys.
Technical Guidance
- Optimal Dosage: Calcium treatment is highly sensitive. An underdose leaves harmful Al2O3 inclusions, while an overdose creates large, potentially harmful calcium sulfide or lime-based inclusions. The optimal residual Ca range in the steel is often measured in very narrow parts per million (ppm) ranges (e.g., 5 ppm to 20 ppm).
- Pre-conditions: Calcium treatment is only effective after the steel has been fully deoxidized (typically with Al) and the oxygen activity is very low.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
