RAXON CLEANMELT™ DX SERIES



De-Oxidized Metallurgical Flux for Clean, Safe & Efficient Steel Melting



PRODUCT INTRODUCTION



RAXON CLEANMELT™ DX Series is a thermodynamically engineered de-oxidized metallurgical flux developed specifically for modern induction furnace steel melting, where raw materials such as sponge iron and pellets contain elevated levels of silica (SiO₂) and alumina (Al2O3). 


These impurities, if not chemically controlled, lead to high-viscosity slag, furnace boiling, slag jamming, refractory attack, increased power consumption, and unsafe operating conditions. 


CLEANMELT DX addresses this challenge at the chemical reaction level, ensuring clean molten steel, controlled slag behavior, safer furnace operation, and consistent casting quality. 


WHY CLEANMELT DX IS REQUIRED (CURRENT INDUSTRY REALITY) 


Due to deeper mining and ore quality variation, today's sponge iron and pellets typically contain:


  • Higher SiO

  • Higher Al₂O

  • Higher oxide load (FeO, MnO) 


When charged into induction furnaces, these oxides cause: 


  • Formation of sticky, high-viscosity slag

  • Slag jamming at slag door

  • Violent furnace boiling & foaming

  • Increased operator safety risk

  • Accelerated refractory erosion

  • Higher electrical power consumption

  • Poor billet surface & internal defects 


Mechanical control cannot solve this problem. Only controlled metallurgical chemistry can. 


CLEANMELT DX-METALLURGICAL DESIGN PHILOSOPHY


CLEANMELT DX is designed on three core metallurgical principles:


  1. Slag Chemistry Correction

  2. 2 Oxygen & Oxide Reduction

  3. 3. Refractory interface Stabilization

 

CLEANMELT DX contains a precisely balanced blend of:



Calcium Aluminate (CaO-Al₂O, System)

Converts acidic slag into basic, free-flowing slag

Absorbs silica and alumina efficiently

Magnesium Oxide (MgO Stabilizers)

→ Forms a protective MgO layer at refractory interface

Prevents chemical erosion and lining wash-out

Controlled Fluoride (CaF2-limited & safe %)

Reduces slag viscosity

Improves slag mobility without refractory damage

High-Purity Carbon Reductants

Removes dissolved oxygen

Reduces FeO back to metallic iron

Optional SiC/FeSi (grade-specific)

Enhances de-oxidation kinetics.

→ Improves melt cleanliness in critical heats
METALLURGICAL REACTIONS (SIMPLIFIED & PRACTICAL)
CaO + SiO₂
→ CaSiO
Converts sticky acidic slag into free-flowing basic
slag
CaO + Al2O3→ Stable Calcium Aluminate Phase
Prevents alumina-based slag jamming
C+FeO Fe + CO↑
→ Increases metal recovery
Removes oxygen from molten bath
MgO Refractory Stabilization Layer
Minimizes lining wear and hot-spot formation


WHAT HAPPENS INSIDE THE FURNACE (OPERATIONAL IMPACT)
After CLEANMELT DX addition:


  • Slag loosens immediately

  • Furnace boiling stabilizes

  • Slag door jamming stops.

  • Bath becomes calm and controllable

  • Oxygen level drops rapidly

  • Operators work in a safer environment

 

PERFORMANCE BENEFITS (PLANT-PROVEN)


  • Clean Melting

  • Dissolved oxygen removed efficiently

  • Non-metallic inclusions absorbed into slag

  • Produces homogeneous, clean molten steel.

  • Electrical Power Saving (6-12%)

  • Lower slag resistance improves heat transfer

  • Faster melting and refining cycles

  • Reduced kWh per ton

  • Improved Casting Quality

  • Reduction in pinholes & blowholes
Improved billet surface finish

  • Stable CCM operation

  • Better rolling performance

  • Furnace Protection

  • MgO-CaO protective slag layer

  • Reduced acidic slag attack
15-20% increase in lining life

  • Lower patching frequency & downtime