Technology Development for Chromium Ore Agglomeration Using Bentonite

Bilyalov, K. S.; Kaliakparov, A. G.; Panfilov, V. P.; Suindikov, D. B.; Baimagambetov, K. N.

doi:10.1007/s11015-023-01530-3

Cited by 2 publications

(1 citation statement)

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“…It has been observed that the utilization of a metalized product, derived from enriching metal concentrates in slag and varying in quality within the charge of the ore-smelting furnace, results in decreased specific energy consumption for melting ferroalloys, alongside an increased furnace capacity. Consequently, the introduction of partially or fully reduced material into the ore-smelting furnace for remelting purposes will reduce specific energy consumption for ferrochromium melting and enhance its capacity [3][4][5][6][7][8][9][10][11][12][13].…”

Section: Introductionmentioning

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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