Thermodynamic modeling of phase composition for Fe-Ca-Si-Al system

In this paper, theoretical studies on the construction of phase structure diagrams of the Fe-Ca-Si-Al system as modeling composition of alloy by Thermodynamic-diagram analysis (TDA) were carried out. TDA analysis allows predicting the optimal composition of alloys using phase structure diagrams of the multicomponent systems. TDA excludes complex mathematical apparatus. Also, TDA allows to obtaine data for the Fe-Ca-Si-Al system, a diagram of phase relationships, each elementary subsystem of which is independent. By analyzing the binary systems, the state diagram of Fe-Ca-Si-Al metal system was constructed, which simulates the final phase composition of the ferroalloy. The reliability of the effectiveness of these methods is confirmed by large-scale laboratory melting tests

Thermodynamic modeling of phase composition for Fe-Ca-Si-Al system

In this paper, theoretical studies on the construction of phase structure diagrams of the Fe-Ca-Si-Al system as modeling composition of alloy by Thermodynamic-diagram analysis (TDA) were carried out. TDA analysis allows predicting the optimal composition of alloys using phase structure diagrams of the multicomponent systems. TDA excludes complex mathematical apparatus. Also, TDA allows to obtaine data for the Fe-Ca-Si-Al system, a diagram of phase relationships, each elementary subsystem of which is independent. By analyzing the binary systems, the state diagram of Fe-Ca-Si-Al metal system was constructed, which simulates the final phase composition of the ferroalloy. The reliability of the effectiveness of these methods is confirmed by large-scale laboratory melting tests

Thermodynamic diagram analysis (TDA) of MnO–CaO-Аl2O3-SiO2 and phase composition of slag in refined ferromanganese production

The research presents the calculations of the analytical expressions of the oxide system MnO-CaO-Al2O3-SiO2 and the phase compositions of the slags from the production of refined ferromanganese. It is determined that the system under consideration is divided into 19 elementary quasi-systems consisting of incongruently melting and congruently melting compounds. The sum of the relative volumes of the elementary tetrahedron of the MnO-CaOAl2O3-SiO2 system equals one (1,000000), which confirms the accuracy of the performed calculations. Quasi-volumes in the system MnO-CaO-Al2O3-SiO2, simulating the composition of the resulting slag in the process of metallothermic recovery of manganese concentrates are found

Development of Smelting Technology of Complex Ferroalloy with the Use of High-ash Coals

The article presents the results of studies that contribute to solving the problem of extraction of aluminum from the ash part of high-ash coals and its further application in ferrous metallurgy. Technologies of obtaining multicomponent complex alloys, including ferrosilicon aluminum, aluminosilicate manganese, and aluminum-silicon-chrome were described in detail. These complex alloys are designed for deoxidation and partial alloying of steel, as well as for the metal-thermal production of various ferroalloys. The main charge material for their production is high-ash coals, which are not used in the national economy and belong to man-made waste. The content of solid carbon in high-ash coals is sufficient for the passage of all reduction reactions, which eliminates the use of expensive coke from the process chain. The use of cheap materials and the refusal to use metallurgical coke allows smelting complex alloys at a relatively low cost. The article also presents the results of a series of large-scale laboratory and pilot tests on the smelting of the above complex alloys using high-ash coals from various coal basins of Kazakhstan. A detailed analysis was made to identify the advantages and disadvantages of the developed technologies in comparison with their analogues. Keywords: complex alloy, high-ash coal, ferrosilicon aluminum, aluminum-siliconchrome, aluminum-silicon-manganese, slag-free proces

Application of the Aluminosilicon Manganese to Obtain Refined Grades of Ferromanganese

This work is dedicated to improving the smelting technology for refined ferromanganese grades through the use of a special complex reducing agent. Laboratory scale experiments were carried out on the smelting of refined ferromanganese using a briquetted charge. Fine fractions (0–5mm) were used for briquetting manganese ore and alumosilicomanganese alloy (AlSiMn). During the experiment were used laboratory installation “HYDROPRESS 50” and coreless induction furnace IUP-25. At the temperature of 1350∘C, the beginning of the charge melting was noted, and at the temperature of 1450∘C, the formation of a liquid melt. According to the chemical analysis, metal samples fully comply with the requirements of the standard. The progress of process parameters has been achieved: the rate of manganese extraction from ore is 70% (according to the traditional technology, it is 55%); slag/metal ratio is 1.8–2.0 (according to the traditional technology, it is 2.2–2.5); known values of slag basicity are 1.5–1.6. Laboratory melting slags were obtained in a stony state with no signs of breaking. As the outcome of this work, a high efficiency of using the reducing agents based on silicon and aluminum in refined ferromanganese smelting, as well as the use of primary manganese ores from Ushkatyn III deposit for smelting refined ferromanganese, allow reducing the lime consumption up to 40% due to the high content of calcium oxide in ore. Keywords: refined ferromanganese, alumosilicomanganese alloy, manganese ore, briquette, sla

Experimental melting of high-silicon ferromanganese with the use of ferromanganesian ore and manganese slag

This work presents the results of smelting ferromanganese from high-silica iron-manganese ores with 36 % manganese content by the flux method. The Shubarkol deposit coal and metallurgical coke as reducing agents were used. The fluxing material was solid slag from the smelting of medium-carbon ferromanganese. The technological modes of the smelting process are established. The optimal composition of the charge was determined. As a result of the theoretical and experimental studies, the tasks have been solved completely - the smelting technology of high-silicon ferromanganese was developed and tested using a substandard raw materials, such as iron-manganese ores and flux

Melting of ferrosilicon manganese with the use of high ash rock coal as a reducing agent

A study of the process of smelting ferrosilicon manganese with the use of high ash rock coals as a reducer instead of traditional coke was carried out. The physicochemical properties of coke from high-ash coals of the Kuu-chek deposit have been studied. The fundamental possibility of its application for the production of standard ferrosilicon manganese in large-scale laboratory conditions has been shown

Studying phase structure of burned ferrous manganese ores by method of nuclear gamma-resonance spectroscopy

In the given article there are presented the results of studying the phase structure of burned ferrous manganese ores of Zhomart and Zapadny Kamys deposits of by the method of Mossbauer spectroscopy. There is established a variety of iron location forms in the studied materials and their quantitative content that allows to define the degree of completing regenerative processes at magnetizing roasting, and also the processes of formation of solid solutions (Fe₁-_XM_X₃O₄ and stabilization of Fe₁-_XO from eutectoid disintegration at cooling

Industrial smelting tests and organization of production of ferrosilicon aluminum (FSA) in Kazakhstan

Results of the industrial tests on production development of ferrosilicon aluminum alloy are showed. The made tests on smelting of ferrosilicon aluminum in electric furnaces with 1,2, 5 and 9 MVA showed a basic possibility to receive alloy of FS55А15, FS55А20 and FS65А10 grades with using of the carbonaceous raw materials in Saryadyrsky and Ekibastuz coal fields. The optimum parameters of the smelting process of FS55А15, FS55А20 and FS65А10 alloys were defined at the Ekibastuz mini-plant and “KSP Steel” LLP. The average power consumption varied within the interval of 9,1 - 12 MWh per 1 ton of alloy depending on a smelting grade of alloy. Increase in aluminum content in alloy composition might be with the rising in ash level of carbonaceous raw materials. The smelting process is characterized with hot furnace condition and active release of alloy

Recovery of low-carbon ferrochrome with multi-component aluminum-silicon-chrome (Al - Si - Cr) alloy

The paper describes pilot smelting of low-carbon ferrochrome (LCFC) with new type of reductant – multi-component aluminum-silicon-chrome alloy (FASCh). Provisional calculations confirmed by results of pilot smelting show that use of FASCh alloy helps to stabilize LCFC slag and prevent its decomposition. Due to high Al content in FASCh the phase area of slag shifts from dicalcium silicate (larnite- Са2SiO4) area into the helenite area (2 CaO ∙ Al2O3 ∙ SiO2)