Formula Used
Each material contributes a recovered element mass. Moisture, contamination, process loss, purity, and recovery modify that contribution. The calculator then divides element mass by retained batch mass.
Element mass = Material mass × Element fraction × Purity × Recovery × Retained charge factor Final element % = Total recovered element mass ÷ Final retained batch mass × 100 Required additive mass = (Target fraction × Current batch mass − Current element mass) ÷ (Effective additive fraction − Target fraction × Additive retained factor)
How to Use
- Choose the required calculation mode.
- Add every tracked element and its limits.
- Enter each charge material and composition.
- Apply realistic recovery and loss assumptions.
- Set costs, inventory, and furnace capacity.
- Submit the form and review all warnings.
- Export the result for production records.
Worked Example
A steel melt contains chromium below its target. Ferrochrome supplies chromium with a stated recovery. The required addition raises the projected melt composition.
| Input | Example Value |
|---|---|
| Initial melt mass | 1,000 kg |
| Initial chromium | 0.72% |
| Target chromium | 1.00% |
| Ferrochrome chromium content | 68% |
| Recovery | 92% |
Common Alloy-Blending Mistakes
Do not mix mass percentage with atomic percentage. Confirm every input uses the chosen mass basis. Review laboratory uncertainty before releasing production batches.
Recovery rarely equals the supplier composition. Furnace practice changes oxidation and slag losses. Use plant data whenever reliable records exist.
Unlisted elements remain inside the balance metal. Large negative balances indicate inconsistent inputs. Verify compositions before trusting the calculated recommendation.
Frequently Asked Questions
1. What does mass balance mean?
It tracks every entered mass through additions and losses. Retained material equals tracked elements plus the remaining balance. Large differences require input review.
2. Can it blend several alloys?
Yes. Add multiple source rows for scrap, virgin metal, returns, or master alloys. Each row can use separate recovery settings.
3. Does it support custom elements?
Yes. Add any element symbol or descriptive name. The result table follows the entered element order.
4. How are process losses applied?
Moisture and contamination are removed first. Process loss then reduces retained charge mass. Element recovery applies to the remaining element mass.
5. What is untracked balance?
It represents base metal and unlisted constituents. It is retained mass minus tracked element masses. A negative value signals inconsistent assumptions.
6. Can it calculate dilution?
Yes. Choose dilution and enter the diluent element concentration. Pure base metal normally uses zero percent.
7. Is optimization exact?
The optimizer uses a constrained numerical approximation. Locked masses and inventory limits remain active. Conflicting targets may produce the closest feasible blend.
8. Can results be exported?
Yes. Copy, CSV, PDF, and print controls are included. Exports contain the calculated composition summary.
9. Should laboratory results override this calculation?
Yes. This tool supports planning and checking. Final production decisions should use verified sampling and approved metallurgical procedures.