Figure 1

Front side view of

Elkem
re-blending and antisegregation alloy hopper.
Dimensions: approx. 50
inches square and 78
inches tall.
Practical Capacity:
2 supersacks MgFeSi @
3000 lb. each. A
supersack can be drained
when the knives inside the
hopper are totally visible.

Figure 2
Top view showing
knives for cutting
open the bottom of a
supersack at remixing positions

Figure 3
Alloy flow control into the trough, and
the trough discharge opening. The flow
control should be set so that the trough
is emptied at least 2 times per
treatment batch.

Figure 4
Lowering a supersack of alloy
into the hopper.

Figure 5
Operator raking alloy out
of the trough. Each rake
stroke should be the full
length of the trough.

Optimally Sized MgFeSi Alloys

When MgFeSi alloys are crushed and screened, there are important considerations
regarding alloy performance and costs. If alloys are processed such that there is a high
removal rate of undersize, the cost of the alloy will be increased. Thin CastingTM and the
use of high efficiency crushing systems can help optimize the yield of MgFeSi alloy
during production to minimize alloy production costs and foundry prices.
Elkem has learned that thin castTM alloys which are processed to a wide size distribution
provide higher Mg recovery than sizes which are too coarse or too fine. This is
believed due to a quieter reaction from the faster frozen alloy as well as the greater
packing density from a wide distribution of sizes. It is believed particularly important to
avoid alloy which contains only coarse particles, as the tendency for these particles to
float is increased. Floating particles generate flare with reduced Mg recovery.
Summary:
1. Thin casting and crushing to a high yield of MgFeSi can lower MgFeSi costs and
prices to foundrymen.
2. Using a wide distribution of sizes results in dense packing of alloy can increase
recovery and reduce usage.
3. Lower price and lower usage at the same time provide the opportunity for
considerable savings.
To gain these benefits, the size distribution for each treatment must be similar. This
means that segregation of the different alloy sizes must be minimized, and means to remix sizes employed.
Because the size distribution of MgFeSi is so important, Elkem shows the size
specification and actual size distribution on the quality control certificate for each lot.
An example of this portion of the quality certificate is shown below.

How Do Alloy Sizes Segregate?

MgFeSi alloys are most often sold in supersack packaging. These are provided in a
variety of styles and sizes. When these packages are filled with alloy, there tends to be a
segregation phenomena which results in more coarse particles along the outside walls of
the supersack and more fine particles in the center of the sack. This is shown
schematically in figure 1. As alloys are subject to the motions involved with
transportation, the finer sizes may also tend to segregate to the bottom of the package.
This effect can be magnified when alloy is removed from the top of the supersack, with
the last material rich in finer sizes. This is shown in figure 2. While this method is not
recommended, where it is done, an effort should be made to scoop material from both the
sides and the center, to attempt to remix coarse and fine size fractions. It is recommended
that when little material remains in the bottom of the bag, that it be added to the top of the
next bag where some re-mixing of sizes can be done. Note that red bands indicate coarse
alloy and blue bands indicate finer alloy.

Figure 1

Figure 2

When alloy is discharged from the bottom of the bag using a discharge spout built into the
bag, or from a hopper knife located in the center of the bag, it is possible that further
segregation of sizes will occur. This is shown in figure 3. In this case the finer sizes tend
to discharge first and the coarse sizes later. If alloy is discharged into another container
such as a bottom discharge hopper, the same effect shown in figure 1 will be repeated,
only the effect will be magnified.
Figure 3, showing the finer material discharging first, and the coarse material last

How Should Alloys Be Handled To Minimize Segregation or

To Re-mix Segregated Sizes?
Elkem recommends that bottom discharge steel bins be used to store and dispense
MgFeSi alloys. Figure 4 , side view, shows the re-blending effect during supersack
discharge which can be gained by using multiple knives in the top of the bin. These are
place midway between the center and the side of the bag, in both side and end view
directions. This makes 4 knives in total, which open 4 discharge holes in the bottom of
the supersack. The end view shows how alloy can be further re-blended by using a rake to
pull alloy out across the full length of the discharge trough. The re-blended material falls
into a pail, which sits on a scale below the trough. This requires considerably less effort
than shoveling alloy from a bin discharge trough, while minimizing spillage.
Figure 4, front view
Re-blend during bag discharge

side view
Re-blend during hopper discharge

supersack

Steel
hopper
knives