Magnesium (metal) is known for its high affinity to oxygen and high vapour pressure of molten Mg (alloys) causing operational problems.

Currently SF6 based gas is used by most magnesium die casters for protection against oxidation of molten magnesium metal. Until recently the use of SF6 was not considered to represent any environmental hazard being non-toxic and without negative impact on the working atmosphere in the foundries. However, due to its very high calculated greenhouse warming potential strict restrictions on the use of the gas in appiications causing emission to the atmosphere are expected in the near future.

Consequently, a search for an alternative protection medium has focused on switch back to SO2 originally applied by the industry prior to the introduction of SF6 gas.

It is well known that SO2 atmosphere strongly reduces the oxidation of molten magnesium by modifying the surface film and that producers of primary metal, sand and die casters have been using SO2 in gas form or generated (in situ) by adding sulphur powder to furnaces.

SO2 is, however, toxic. In high concentrations and in contact with humidity it results in enhanced corrosion of steel equipment. The present occupational exposure iimit in Norway is 2 ppm over an 8 hours period of time corresponding to a concentration of 5 mglm3, and corresponding limits in Germany and North America are similar.

Consequently, it is an object of the present invention to provide a new and improved method of mixing and maintaining a pre-set level of SO2 in an air mix within narrow tolerances.

Another object of the present invention is to provide an apparatus ensuring environmentally safe mixing and feeding of the SO2 air mix into the Mg-furnaces/vessels.

Still another object of the present invention is to provide an improved method of fluxless melting of magnesium substantially reducing problems connected to formation of scaling on the crucible walls.

These and other objects and features are met by provision of the new method and apparatus according to the present invention as it appears from the attached patent claims 1-5.

The new method of mixing and maintaining of the pre-set level of SO2 in the air mix will now be described and readily understood from the following description under reference to the accompanying drawings, Figs. 1-3, and preferred embodiments/modes of operation, where Fig. 1 shows schematically a flow chart of the mixing/feeding process, Fig. 2 illustrates schematically in a vertical, partial cross-section a feeding arrangement (apparatus) usable in the process of fluxless melting of magnesium, and Fig. 3 shows schematically the applied furnace/vessel in a horizontal cross- section along line I-I Referring to Fig. 1 illustrating schematically a flow chart of the mixing/feeding process applicable according to the present invention, a melting furnace 1 is equipped with charging device 2 to feed solid magnesium into the furnace, transferring device, e.g. transfer tube 3 to move subsequently the Mg-melt into and adjacent casting unit (furnace) here depicted as 4. By means of e.g. so-called gas displacement (metering) pump 5 the melt is fed in a controlled manner (doses) into any suitable casting equipment, e.g. the shown high pressure die casting machine 6.

According to the present invention and as an example of a preferred embodiment an apparatus arrangement for controlled mixing/feeding of the mixture SO21dry air comprises a compressor 13 and a pressure bottle 14 providing (dry) air and SO2 gas, respectively, into the mixing device 9 comprising a mass flowmeters 10 and 12 for the air and SO2, respectively, and a control steering unit 11 to ensure an adequate pre-set concentration of SO2 in the gas mixture. The resulting gas mixture is then conducted through a feeding line 8 and distributed by means of manifolds (flowmeters) 7 and customary valves into the actual (part of) furnaces 1 and 4.

This is achieved by applying a double set of mass flowmeters 10,12 where the mass flowmeter 10 controlling the air flow is also in control of the mass flowmeter 12 so that the concentration of SO2 in the gas mixture will never exceed the pre-set level. In the case of an emergency situation, e.g. break down on the feeding line/equipment providing dry air, this "master" flowmeter 10 will automatically switch off also feeding of SO2.

As "dry air" referred to in the description air having a dew point - 30"C is applied.

Using this sophisticated mixing unit ensures that the SO2 concentration may be kept very low and the distribution of the protection gas to the liquid. Mg surface is so uniform that emissions from furnace atmospheres to surroundings will be negligible and represents no hazard for foundry personnel.

With references to Figs. 2 and 3 illustrating schematically an arrangement of feeding means usable in the process of feeding/distribution of SO2/air mixture according to the present invention, Fig. 2 shows schematically in a partial, vertical cross-section the furnace 1 as a steel vessel accommodated in a thermally insulated furnace shell 20. The melting furnace is provided with a charging device 2 to introduce solid Mg into the furnace, a baffle plate 15 dividing the furnace into a charging sector and a main body of the melting furnace where the furnace design/configuration should assure a high ratio volumelsurface area in order to minimise reaction(s) occurring between molten Mg and the atmosphere.

Consequently, all lids and hatches must also be well tightened as illustrated in an exploded view showing details of lid seals 16. The gas mixture is provided to the furnace(s) through a sophisticated distribution system allowing the gas mixture to be evenly distributed close to the melt surface, e.g. by means of a ring tube 17 positioned along the furnace periphery in the vicinity of the melt surface as shown in Fig. 3. Fig. 3 illustrating schematically the applied melting furnace 1 in a horizontal cross-section taken along line I-I in Fig. 2, further depicts the charging zone (device) 2, dividing baffle plate 15 and a lid 19 for eventual removal of dross/sludge from the furnace.

The ring tube 17 is provided with a plurality of apertures ensuring an even distribution of the protective gas mixture by controlled directional impingement of the melt surface.

Experiments conducted in industrial size furnaces with SO2 air mixtures applying the above method confirm that the SO2/air protection atmosphere protects effectively molten magnesium surfaces against oxidation.

The following reactions between the metal and the gas mixture may occur: Mg(l)+O2+SO2 -> MgSO4(s) MgSO4(s) + Mg(l) o MgO(s) + Mg(s) MgS(s) + O2 + SO2 -> MgSO4(s) MgO(s) + SO2 + O2 -> MgSO4(s) It is believed that a sort of "self-reparation" of possibly disrupted/cracked layers of MgO(s) + MgS(s) occurs due to a further reaction between magnesium evaporated through such cracked opening and the cover gas.

Example 1 Summary of pilot trials conducted in full scale furnaces in laboratory: Temperature of the melt 655-690°C Gas mixture flow rate /m2 melt surface 10l/min SO2 concentration in the gas mixture 0.5-1.7% Duration of trials 47 hours Example 2 Tests have been carried out on an industrial scale in a hot-chamber casting machine. A mixing unit built according to the present invention provided SO2ldry air mixture for the furnace. Gas samples were frequently monitored (every four hours) both from the mixing unit, the furnace atmosphere and the working atmosphere as well.

Melt surface area 0.3 m2 Melt temperature 660"C Flow rate of the gas mixture 7.3 I/min Duration of trials 3 days SO2 concentration in the (dry) air mixture : 0.8% SO concentration in the atmosphere 0.2 ppm Gas samples of the atmosphere were collected at three differenct locations in the foundry - at operator level, in the vicinity of the charging lid and approximately 3 m above the floor. No significant differences were measured in the gas concentrations between the locations indicating a safe, controlled operation and an adequate ventilation of the foundry hall.

A controlled diluted SO lair mixture was provided and maintained during the test periods, something being of crucial importance also for the life time of the applied steel equipment.

It is well known that both SO and SF6 in contact with humidity will accelerate steel corrosion. Deposits and reaction products may be formed on e.g.

cruciblelfurnace walls, something which under unfavourable conditions can lead to metal eruptions from the furnace. Consequently, high concentration of SO2 combined with high humidity should be avoided.