Influence of process parameters on impurity level in ferrochrome production-An industrial-scale analysis

Kumar, Pankaj; Sahu, Nilamadhaba; Roshan, Aditya; Rout, Biranchi Narayan; Tripathy, Sunil Kumar

doi:10.1080/08827508.2021.1913154

Cited by 4 publications

(3 citation statements)

References 24 publications

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“…The composition of the slag also affects the silicon content. Higher levels of basic oxides like CaO or MgO in the slag result in lower silicon contents in the slag, while elevated contents of SiO 2 result in higher contents of silicon in the metal 13 . Since the addition of oxides in the process remained the same, except for elements that are part of the reducing agents, an influence of the chromite concentrate or fluxes seems neglectable.…”

Section: Resultsmentioning

confidence: 99%

Enabling CO2 neutral metallurgy for ferrochromium production using bio-based reducing agents

Sommerfeld,

Botinha,

Friedrich

2024

Sci Rep

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The metallurgical industry is a major source of anthropogenic greenhouse gas emissions. This study explores the replacement of fossil-reducing agents with potentially CO2-neutral bio-based reducing agents. Since reducing agents remove oxygen bonded with metal oxides present in the ore, they are a necessity for the production of metallic elements. The investigated metal is chromium, a major part of stainless steel, and therefore a highly relevant element for the transition from a fossil-based energy system to a renewable one. The state-of-the-art smelting reduction and pre-reduction process followed by subsequent smelting using various reducing agents are investigated in this article. The obtained products, metallurgical efficiencies, energy consumption and off-gas generation were compared. While the products produced with bio-based reducing agents are comparable with the reference trials using metallurgical coke regarding the major components in the metal, the concentration of detrimental phosphorus is significantly higher using bio-based reducing agents. The metallurgical efficiency of the process is comparable to the usage of bio-based reducing agents and coke. However, the energy consumption and the generation of off-gas is higher, when coke is replaced by bio-based reducing agents.

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Section: Resultsmentioning

confidence: 99%

Enabling CO2 neutral metallurgy for ferrochromium production using bio-based reducing agents

Sommerfeld,

Botinha,

Friedrich

2024

Sci Rep

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“…The specific energy consumption of the pilot 0.2 MVA furnace decreased by a factor of 1.79 during the melting of high-carbon ferrochromium compared to the power consumption during the remelting of chromite ore. This means that the furnace is more efficient and requires less energy to melt the high-carbon ferrochromium [41].…”

Section: Methodsmentioning

confidence: 99%

Pilot Tests of Pre-Reduction in Chromium Raw Materials from Donskoy Ore Mining and Processing Plant and Melting of High-Carbon Ferrochromium

Shabanov,

Makhambetov,

Saulebek

et al. 2024

Metals

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Experiments were conducted to pilot the initial reduction in chromium raw materials using the innovative Hoganas technology in a tunnel furnace. To simulate the process, a gas-fired bogie hearth furnace was employed. Technological containers made of silicon carbide crucibles were utilized. Sixteen different combinations of ore and coal mixtures were employed for the initial reduction process. Their total mass was more than 20 tons. Their heat treatment was performed at different temperatures and durations. During the pilot tests, the possibility of achieving chromium metallization was confirmed. Thus, it explains the application of a pre-reduction instead of the sintering or charge heating before the ferrochromium melting, i.e., the power consumption is minimized during the final remelting of the product in DC furnaces. The pilot melting of three batches of the pre-reduced chromium raw materials with various chromium metallization degrees has been tested in the ore-smelting furnace at Zh. Abishev Chemical–Metallurgical Institute (Karaganda). The capacity was 0.2 MVA. To evaluate the technical and economic efficiency of remelting pre-reduced chromium raw materials in commercial DC furnaces, a specific batch of primary ingredients for producing high-carbon ferrochromium, including chromite ore, coke, and quartz flux, was successfully melted in a segregated phase. As a result of the study, it was found that the specific energy consumption for melting high-carbon ferrochromium in the pilot furnace depends on the chromium metallization degree. The researchers tested a range of chromium metallization degrees from 0 to 65% and determined the corresponding specific energy consumption for each degree. Using the data obtained from the study, the researchers were able to assess the melting indexes of high-carbon ferrochromium in a larger 72 MW furnace. They found that by using a pre-reduced product with a chromium metallization degree of 65%, it was possible to reduce the specific energy consumption by half, to around 3.4 MW·h per ton of chromium. Overall, this study highlights the importance of considering the chromium metallization degree when determining the specific energy consumption for melting high-carbon ferrochromium. By optimizing the metallization degree, significant energy savings can be achieved, leading to more efficient and sustainable production processes.

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“…The main mineral composition in the slag is diacalcium silicate (2CaO·SiO 2 ), followed by a small quantity of magnesium rose olivine (3CaO·MgO·SiO 2 ) and calcium-aluminite (2CaO·Al 2 O 3 ·SiO 2 ). Therefore, the low carbon ferrochrome slag has high potential activity and available value [ 2 , 3 , 4 ]. The chemical composition of the high carbon ferrochrome slag is mainly SiO 2 , Al 2 O 3 , and MgO.…”

Section: Introductionmentioning

confidence: 99%

Preparation and Hydration Mechanisms of Low Carbon Ferrochrome Slag-Granulated Blast Furnace Slag Composite Cementitious Materials

Ren

Wang

et al. 2023

Materials

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Low carbon ferrochrome slag (LCFS) is the metallurgical waste slag from the carbon ferrochrome alloy smelting process. Compared with high carbon ferrochrome slag, LCFS has great potential as cementitious material; the chemical compositions of the two types of slag are quite different. In this research, composite cementitious materials are prepared which use low carbon ferrochrome slag and granulated blast furnace slag (GBFS) as the main raw material. Steel slag mud (SSM) and flue gas desulfurization gypsum (FGDG) are used as the activator. In order to find the variety rule of compressive strength on the composite cementitious materials, a three-factor three-level Box-Behnken design is used to discuss the following independent variables: LCFS content, GBFS content, and water-binder ratio. Moreover, the hydration characteristics of the LCFS-GBFS composite cementitious materials is studied in this paper in terms of hydration product, micromorphology, and hydration degree, based on multi-technical microstructural characterizations. The results show that the compressive strength of the LCFS-GBFS composite cementitious materials is significantly affected by single factors and the interaction of two factors. The mechanical property of the mortar samples at 3, 7, and 28 days are 26.6, 35.3, and 42.7 MPa, respectively, when the LCFS-GBFS-SSM-FGDG ratio is 3:5:1:1 and the water-binder ratio is 0.3. The hydration products of LCFS-GBFS composite cementitious materials are mainly amorphous gels (C-S-H gel), ettringite, and Ca(OH)2. With the increase of LCFS content, more hydration products are generated, and the microstructure of the cementitious system becomes more compact, which contributes to the compressive strength. The results of this research can provide a preliminary theoretical foundation for the development of LCFS-GBFS composite cementitious materials and promote the feasibility of its application in the construction industry. Deep hydration mechanism analysis and engineering applications should be studied in the future.

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Influence of process parameters on impurity level in ferrochrome production-An industrial-scale analysis

Cited by 4 publications

References 24 publications

Enabling CO2 neutral metallurgy for ferrochromium production using bio-based reducing agents

Enabling CO2 neutral metallurgy for ferrochromium production using bio-based reducing agents

Pilot Tests of Pre-Reduction in Chromium Raw Materials from Donskoy Ore Mining and Processing Plant and Melting of High-Carbon Ferrochromium

Preparation and Hydration Mechanisms of Low Carbon Ferrochrome Slag-Granulated Blast Furnace Slag Composite Cementitious Materials

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