Chromium quality and ferrochrome quality chromium ore is divided into two types. Pdf exergy and its efficiency calculations in ferrochrome. Evaluation of the furnace method for the production of low. Marie has submitted a request to noront resources inc. The vacuum process is based on the solidstate reaction between the carbon in finelyground, highcarbon ferrochrome and oxygenbearing materials to evolve carbon monoxide.
Keywordsferrochrome production, ferroalloy process optimization. A fully 3dimensional cfdbased overall process model for ferrochrome production is proposed, and the potential and limits of the cfd model are a ddressed. The technology of the furnaces is modular in design, most modern, resulting in longer uptime of furnaces, hence optimizing the furnace operation and efficiency. Pdf direct production of ferrochrome by segregation reduction. Due to high quality it is a reliable and economical alternative instead of. The technology of the furnaces is modular in design, most modern, resulting in longer uptime of furnaces, hence. Ferrochrome is produced using submerged arc furnaces. The process involves segregation reduction of chromite using. The present invention relates to a process for producing lowcarbon ferrochromium, introducing scrap iron or ferrochrome into an electric furnace to produce a molten metal. A process for producing high carbon ferrochrome which comprises feeding continuously to an electricarc furnace a charge mixture consisting of sintered pellets obtained by the reductive calcination of chrome ores, said pellets being those in which about 80 50 mol percent of the total content of the oxygen combined with iron and chromium components has been removed and the two. The main reactions involved in the reduction of iron, chromium and silicon to the metal phase are briefly presented below subscripts x and y.
Especially in 1980s, strong interest was seen in research and implementation of new methods such as plasma smelting, prereduction and direct reduction. Us3523021a us3523021da us3523021a us 3523021 a us3523021 a us 3523021a us 3523021d a us3523021d a us 3523021da us 3523021 a us3523021 a us 3523021a authority us united states prior art keywords ferrochrome percent carbon oxygen method prior art date 19670523 legal status the legal status is an assumption and is not a legal conclusion. Keywords ferrochrome production, ferroalloy process optimization, chrome ore i. Exergy and its efficiency calculations in ferrochrome production. Learning and teaching using process modelling and simulation. The ratio in which the two metals fe and cr are combined can vary, with the proportion of cr ranging between 50 % and 70 %. Analysis of transport phenomena in submerged arc furnace. Appendix 1 for resources about ferrochrome production processes. Highcarbon and charge chrome alloys are generally produced in the conventional smelting process by carbothermic reduction of ferrochrome. The citys reasoning for doing so is that the new facility will create new employment opportunities for the citizens of sault ste. Ferrochrome can react with some acids with the evolution of hydrogen. Low and mediumcarbon content ferrochromium fecr and ferromanganese. The ferrochrome processing facility is planned to produce high carbon ferrochrome and employ approximately 1,500 during construction and between 300 and 500 people fulltime.
South africas chromite mines are operated by a number of smaller companies that focus on the production. Kr101469679b1 low carbonferrochromium manufacturing method. Optimization of process parameter for smelting and reduction of ferrochrome. The global ferrochrome market size was valued at usd 16. The citys reasoning for doing so is that the new facility will create new employment opportunities for the citizens of. Production of ferrochrome ferrochrome fecr is an alloy comprised of iron fe and chromium cr used primarily in the production of stainless steel. Mixing molten chrome ore powder with a reducing agent powder containing no carbon to produce molten ferrochrome melted by a thermite reaction. Analysis of transport phenomena in submerged arc furnace for. However, during the cocktailing step, process temperatures are extremely high. Modelling of the refining processes in the production of ferrochrome and stainless steel 67 is achieved by using chromium as an alloying element. Modelling of the refining processes in the production of. Optimization of process parameter for smelting and reduction. Ferrochrome is produced by electric arc carbothermic reduction of chromite. A vacuum process and manufacturing facilities for the production of lowcarbon ferrochrome are described.
Ferrochrome production for metallurgical applications uses up more than 90% of the worlds chromite output of about 19 m tonnesy. Chromium, chromite mining and ferrochrome production. Optimization of process parameter for smelting and. The growing use of ferrochrome as a source of chromium in stainless steel production is expected to drive market growth. Additional fact sheets summarizing risks to the environment, chromite workers and nearby populations are also available online at. However, during the cocktailing step, process temperatures are extremely high, resulting in rapid deterioration of the ladle. Pdf ferrochrome production is a high energy intensive process. Ferrochrome can react with molten alkalis with the formation of compounds containing chromium vi. Modernday ferrochrome production faces a number of challenges.
Jul 10, 2018 production of ferrochrome ferrochrome fecr is an alloy comprised of iron fe and chromium cr used primarily in the production of stainless steel. However, the importance of low carbon ferrochrome will continue for a few years till the new process of stainless steel manufacture are adopted by all. Ferrochrome imparts the noncorrosive property to stainless steel, and thus most of the ferrochrome produced worldwide is used in the manufacturing of stainless steel. Ferrochrome, or ferrochromium fecr is a type of ferroalloy, that is, an alloy between chromium and iron, generally containing 50% to 70% chromium by weight ferrochrome is produced by electric arc carbothermic reduction of chromite. The transformation of ferrochromium smelting technologies. Ferrochrome is the major source of chromium in the stainlesssteel industry. The total world steel production is presented in figure 2. Ferrochrome production is a high energy intensive process consuming around 3000 to 3500 kwht of electrical energy. This is a twostage process and economically less attractive than the direct smelting process. South africas ferro alloys industry present status and future outlook 5 thus, from very humble beginnings in 1918, the sout h african ferro alloy industry has prospered and grown to become a leading producer of bulk ferro alloys on a global scale. It is known that high temperature processes including production and welding of chromium and chromiumcontaining alloys can lead to generation of fumes containing chromium vi. Ferrochrome is the major chromium source for stainless steel production, and submergedarc furnaces saf are most commonly utilised to smelt chromite ores into ferrochrome by using suitable carbonaceous reductants such as coke.
Introduction rapid growth of the world stainless steel industry during the past two decades posts a high demand on the production of ferrochrome which is the main raw material for. A major part of new process technology has been launched in ferrochrome production. The proposed project noront resources is planning to build a ferrochrome production facility fpf in northern ontario. Manufacture of simplex ferrochrome by the vacuum process. In most cases electric energy is transferred to the process via self baking. Production, characteristics and use of ferrochromium slags 173 2. An alternative to this process is to remelt highcarbon ferrochromium with silica and coke. Low carbon ferrochrome is a primary alloying element in the production of stainless steel. Nonmetallurgical applications consumer only a fraction of chromite production, with the refractory industry accounting for only about 1% and 3% each for the foundry and chemical industries. Cost analysis of chrome ore reduction is one of the important issues facing ferrochrome producers in todays competitive environment. The latter can have a direct bearing on electricity consumption and optimum efficiency of the furnaces.
Petition say no to ferrochrome production in sault ste. Keywordslearning, teaching, process simulation, ferrochrome production i. While the industry has been successful in reducing costs by designing larger and more. Download pdf nptel remember that, i showed a table where i compared process, have produced in an industry, and i am showing here energy requirements for production, sodium metal, nickel cathode, ferrochrome high carbon, ferromanganese, arc, you know ball mill is a ball mill it it it is efficiency cannot be into so much, it has been. The low carbon content in ferrochromesilicon is a consequence of a decreased solubility of carbon due to the increase in silicon content. Jamshedpur, india abstract energy is in the form of sio and co offthe increasing costs of electric energy and continuous. Ferrochrome production is essentially a carbothermic reduction operation taking place at high temperatures. Ferrochrome is produced by smelting of different grades of chromite ore with. Increased ferrochrome production has been achieved by building new furnaces and switching furnaces previously used for other alloys to ferrochrome. Jamshedpur, india abstract energy is in the form of sio and co offthe increasing costs of. Direct production of ferrochrome by segregation reduction. In the combined form of study, there is a much smaller proportion of direct contact teaching, which makes this study much more difficult for students. Duplex process for production of low carbon ferrochrome. Exergy and its efficiency calculations in ferrochrome.
Introduction rapid growth of the world stainless steel industry during the past two decades posts a high demand on the production of ferrochrome which is the main raw material for stainless steel production. The mixing method perrin and duplex processes are most commonly used for the production thereof. Pdf ferrochrome production is a high energy intensive process consuming around 3000 to 3500 kwht of electrical energy. Emissions from all the filters are well below 10 mgnm, maintenance on the filters has been significantly reduce, and extraction volumes from the furnaces have been significantly increased, leading to lower stack temperatures. Much of this depends on quality and various ratios in the actual ore. Chemical reactions in the ferrochrome production process, always result in. In order to adapt to these harsh economic conditions, the industry now places an even greater emphasis on minimizing. Because of the complexity of feed structure and electricalthermalchemical interactions, there exist large gradients and wide distributions of temperature. Due to high quality it is a reliable and economical alternative instead of metallic chromium in superalloy production. Ferrochrome fecr is a corrosionresistant alloy of chrome and iron containing between 50% and 70% chrome. Low carbon ferrochrome production lc fecr lc fecr low carbon ferrochrome is a ferroalloy used to regulate the ratio of chromium in steel production without carbon and other unwanted ingredients.
All the chrome ore in south africa is located in the bushveld igneous complex. Pdf a solid reduction process is described whereby chromite is reduced with the help of calcium chloride to produce ferrochrome alloy. System optimization and installation of gore filter bags resulted in improvements to the baghouse and overall production process. In oxidizing conditions a thin yet dense layer is formed on the surface of the metal if the chromium content of the metal is over approximately 12 w% e. Private communications from industrial sources indicated that the energy expenditure for production of 1 long ton of highcarbon ferrochrome by threephase submerged arc smelting in the simplex process ranges from 4,500 to 6,400 kilowatthours, and an additional 4,000 to 6,000 kilowatthours is required in the process for the oxidation of a. Electrometallurgy and ferroalloys production 3 preface study support to the subject electrometallurgy and ferroalloys production is primarily intended for students of combined studies. Growth in industrialization in emerging economies, especially in asiapacific countries, and increase in production of stainless steel fuel the demand for ferrochrome, thereby. Details of the present ferro alloy industry in south africa are found in the next section. A process for producing high carbon ferrochrome which comprises feeding continuously to an electricarc furnace a charge mixture consisting of sintered pellets obtained by the reductive calcination of chrome ores, said pellets being those in which about 80 50 mol percent of the total content of the oxygen combined with iron and chromium components has been removed and the. Ferroalloy is used to physically introduce or carry that element into molten metal, usually during steel manufacture. Zimbabwes major producers of ferrochrome cut back on production approx. The production of steel is the largest consumer of ferrochrome, especially the. Keywordsferrochrome production, ferroalloy process optimization, chrome ore i. Ferrochrome is typically produced in south africa from chromite in either a.
In the recent past, china overtook south africa as the worlds leading ferrochrome producer 5. In oxidizing conditions a thin yet dense layer is formed on the surface of the metal if the chromium content of the metal. Lowcarbon lc ferrochromium is typically produced by fusing chromium. Moving forward, key steps include environmental and feasibility assessments, along with community consultation and engagement. Introduction igh carbon ferrochrome hcfecr is produced by carbothermic reduction of chrome ore. Atifcs plant consists of two submerged arc furnaces, each of 24 mva rating. Impact of chromite mining chromite mining is the main raw material used in ferrochrome production.
Most of the worlds ferrochrome is produced in south africa, kazakhstan and india, which have large domestic chromite resources. Ferrochrome fecr is added to stainless steel to enhance its appearance and impart corrosion resistance. Global ferrochrome market 20192023 research and markets. Effect of south africa reductants on ferrochrome production. Cr ore, an oxide of chromium and iron, is reduced by coal and coke to form the ironchromium alloy. On may 7, 2019, it was announced that the company selected sault ste.
Keywordsferrochrome production, ferroalloy process optimization, chrome ore. Increasing amounts are coming from russia and china. Increasing stainless steel production around the globe is the significant factor driving the market growth. The smelting point of the slag has to be higher than the metal smelting point, because metal is heated up by using slag liquid phase. Ferrochrome is produced by smelting of different grades of chromite ore. Oct 15, 2019 the proposed project noront resources is planning to build a ferrochrome production facility fpf in northern ontario. Introduction the metallurgical use of chromium is in the form of ferrochrome for production of stainless. Once noront has established itself as a high quality, consistent ferrochrome producer in the north american market, we plan to double our fpf production, which would increase. Potential toxic effects of chromium, chromite mining and. And removing the slag produced by the thermite reaction. Kr101469679b1 low carbonferrochromium manufacturing.