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Application of the Mining Industry Wastes as Raw Material for Melting of the Complex Fesial Ferroalloys

Machulec B., Bialik W., Gil S.

Archives of Metallurgy and Materials

2018

Vol. 63, iss. 2

975--979

An economical alternative for the steel industry which uses a separate ferrosilicon and aluminum for the deoxidization of steel is a complex deoxidizer in the form of FeSiAl alloys. The effectiveness of complex deoxidizers is higher and they have a positive effect on quality improvement and also for mechanical properties of the finished steel. It is associated with a smaller number of non-metallic inclusions and a more favorable its distribution in the structure of steel. Noteworthy are the waste from the mining industry simultaneously contains SiO2 and Al2 O3 oxides with a few of dopants in the form of CaO, MgO, FeO, TiO2 oxides. These wastes are present in large quantities and can be a cheap raw material for obtaining complex FeSiAl ferroalloys by an electrothermal method. “Poor” hard coal grades which so far did not apply as a reducing agent in the ferroalloy industry because of the high ash content can also be a raw material for the electrothermal FeSiAl process. The electrothermal FeSiAl melting process is similar to the ferrosilicon process in the submerged arc furnace. For this reason, a model based on Gibbs’ free enthalpy minimization algorithm was used to analyze the simultaneous reduction of SiO2 and Al2 O3 oxides, which was originally elaborated for the ferrosilicon smelting process. This is a system of two closed reactors: the upper one with the lower temperature and the lower one with the higher temperature. Between the reaction system and the environment, and between the reactors inside the system, there is a cyclical mass transfer in moments when the state of equilibrium is reached in the reactors. Based on the model, the basic parameters of the electrothermal reduction process of SiO2 and Al2 O3 oxides were determined and a comparative analysis was made towards the ferrosilicon process.

Modelowanie procesu fizykochemicznego wytopu żelazokrzemu w arkuszu kalkulacyjnym Excel

Machulec B., Kopeć G.

Hutnik, Wiadomości Hutnicze

2011

Vol. 78, nr 9

732--734

Bazując na metodzie minimalizacji Gibbsa przedstawiono model fizykochemiczny procesu wytopu żelazokrzemu w piecach rezystancyjno- łukowych. Wykorzystano możliwości pakietu do obliczeń termochemicznych HSC z dodatkiem zawierającym funkcje umożliwiające korzystanie z bazy danych termochemicznych oraz rozwiązywanie zagadnienia minimalizacji Gibbsa bezpośrednio na arkuszu kalkulacyjnym Excel. Model złożony jest z dwóch zamkniętych stref izotermicznych o zróżnicowanych temperaturach, pomiędzy którymi cyklicznie następuje przepływ masy. Uzyskane za pomocą modelu wyniki obliczeń wykazują zadowalającą zgodność z danymi przemysłowymi dotyczącymi uzysku Si oraz jednostkowego wskaźnika zużycia energii.

Based on the Gibbs Energy Minimization Method it has been presented the physico-chemical model of the ferrosilicon smelting process in submerged resistance-arc furnace. It has been used the option of the HSC package for thermochemical calculations with the addition features that allow using of thermochemical database and solving the Gibbs Minimization Problems directly on the Excel spreadsheet. The model is composed of two closed isothermal zones with varying temperatures between which cyclically the mass flow. Obtained with the model calculation results show satisfactory agreement with the industrial data on the Si yield, and the specific energy consumption.