Customer demands for improved casting quality has driven the foundry industry to adopt Clean Steel practices involving ladle metallurgy. However, the process changes are usually accompanied by increased costs and reduced productivity. One solution to the problem is to adopt the ladle furnace technology from minimills for producing low cost high quality steel. A single electrode D. C. ladle furnace has been adapted to treat foundry-sized heats. Argon flowing through an axial hole in the electrode creates a hot stable plasma. Electrolysis effects in D. C. Plasma heating result in exceptionally low sulfur and oxygen contents. The benefits of the process are improved casting quality, improved plant productivity and improved profitability. This paper describes the plasma arc heating and refining process and details the quality and productivity benefits attainable. A cost-benefit analysis is also presented.
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