PRODUCTION OF FERRO ALLOY seminar.pptx

Power point presentation on production on ferdous alloy

1. PRODUCTION OF FERRO ALLOY SAGAR CHAKRABORTY M.E. METALLURCAL ENGINEERING JADAVPUR UNIVERSITY ROLL. NO. -002211302007

2. Content Introduction of Ferro alloy Production Process of Ferro alloy Classification of Ferroalloy Processes by Reductant Type CO2 emission Main ferroalloys Types of Ferro Alloys Complex ferroalloy Uses Of Ferroalloy Application Future market Conclusion References

3. What is ferroalloy ? The word ferroalloy refers to an alloy of iron containing a significant proportion of one or more other elements like silicon, manganese, chromium, aluminum , or titanium. The main applications of ferroalloys occur in the steelmaking process

4. Production of ferroalloy : Ferroalloys are produced generally by two methods : in an open arc furnace In an  submarged arc furnace. All high carbon alloys are produced in submerged arc furnace where the arc is submerged in the charge. for low and medium carbon alloys open Arc furnace are used Blast furnace production continuously decreased during the 20th century, whereas the electric arc production is still increasing. Today, ferromanganese can be still efficiently produced in a blast furnace, but, even in this case, electric arc furnace are spreading. More commonly, ferroalloys are produced by  carbothermic reaction, involving reduction of oxides with carbon (as coke) in the presence of iron. Some ferroalloys are produced by the addition of elements into molten iron.

5. Blust furnace production Ferro manganese can be manufactured in blast furnaces much more economically compared to submerged arc furnaces . Some modifications will be required in the design of conventional blast furnaces for production ferro manganese.

6. Open arc furnace In these furnace, where arc is open, normally ore and lime are melted together in low carbon Ferro Chrome production. The liquid slag is allowed to react with silicon reducer in the ladders. Hydraulic system is different and all the electrode lifted at a time for the movement of furnace. Furnace can be tilting and travelling type.

7. Submerged Arc Furnace for production of ferroalloys classification of submerged Arc furnace open furnace closed furnace semi closed furnace

8. Open type furnace- Most of the Furnace are open type with the Furnace top exposed the reactions gases generated in the Furnace. due to reductions reactions of oxides of ores with carbon are rich in carbon monoxide. the later burns at the surface of furnace top of carbon dioxide . there are advantage also with this type of furnace. Furnace conditions monitoring is easier. Top conditions can be observed continuously. Charge level can be kept as per requirement. Constant poking of charge with stocking car can help in release of gases.

9. Closed typed furnace- In closed furnace, the biggest advantage is conservation of energy. Normally open top furnace are used for Ferro alloys smelting however in view of high calorific value of furnace gas comprising with 80 to 85% carbon monoxide, and to recover the energy, closed top furnace consisting of a domes roof has become popular. Semi closed furnace- Moderation of closed furnace

10. Classification of Ferroalloy Processes by Reductant Type Reduction by Carbon ( Carbothermal Processes) In these processes, carbon is the main reductant of the metal oxides. The overall reaction can be represented as MeO2 + yC =Me + MeCz + CO Reduction by Silicon ( Silicothermal Processes) Silicon reduction of metals from their oxides occurs with the formation of silicon-rich metal melts MeO2 + Si=½Me+ Si + SiO2, and in some cases metal silicides might also form if they are stable at the reaction temperatures. Reduction by Aluminum ( Aluminothermal Processes) Reduction by aluminum proceeds with the reaction MeO2 + (2x/3)Al=Me + (x/3)Al2O3, which is accompanied by a significant exothermal effect.

11. CO2 Emissions from Ferroalloys Production Ferroalloys production is an energy-intensive industry with a high consumption of electricity but only a moderate consumption of coke and minor consumption of other fuels and reductants . This affects direct CO2 emissions. only for direct emissions from the combustion of carbon when coke and eventually coal are used for reduction as well as from electrodes consumption. One has to adding direct emissions generated in electricity production so , depending on the method of electricity generation, the indirect CO2 emissions

12. The main ferroalloys are: FeAl - ferroalluminium FeB –  ferroboron – 12–20% of boron, max. 3% of silicon, max. 2% aluminium, max. 1% of carbon FeCe –  ferrocerium FeCr – ferrochromium FeMg –  ferromagnesium FeMn – ferromanganese FeMo – ferromolybdenum – min. 60% Mo, max. 1% Si, max. 0.5% Cu FeNb –  forroniobium FeNi – ferronickel(and nickel pig iron) FeP –  ferrophosphorus FeSi – ferrosilicon – 15–90% Si FeSiMg – ferrosilicon magnesium (with Mg 4 to 25%), also called nodulizer FeTi – ferrotitanium – 10..30–65..75% Ti, max. 5–6.5% Al, max. 1–4% Si FeU –  ferrouranium FeV – ferrovanadium FeW – ferrotungsten

13. Types of Ferro Alloys Ferroalloys are classified into two main categories, Bulk ferro alloys and Noble ferro alloys. Bulk ferroalloys is majorly used in stainless steel & carbon steel. Most of the noble ferroalloys are made from rare-earth minerals and are expansive to produce as compared to bulk ferroalloys.

14. Bulk Ferroalloys Ferromanganese Silicomanganese Ferrosilicon Ferrochrome Chargechrome

15. COMPLEX FERROALLOYS Complex ferroalloys and master alloys are used in steel and special alloys manufacturing for alloying (and composition adjustment) and refining (oxygen, sulphur, etc. removal) purposes. Historically, complex ferroalloys have been made by fusing (smelting) several ferroalloys and then tapping and casting, and classifying them into relevant sizes. However, this method is not very economicdonce produced, ferroalloys must be again heated, melted, and processed. This leads to substantial energy and material losses and possibly more environmental pollution.

16. Uses Of Ferroalloy FERRO SILICO MANGANESE Melting Range -1130-1230°C SPECIFIC GRAVITY - 6.35 Used mainly in low carbon grades of steel due to the low carbon content of the alloy, nominally C 1.5%-2.0%, or where specific alloying characteristics are required.

17. FERRONIOBIUM - Melting Range -1500-1550 C SPECIFIC GRAVITY –8.2 Also called Columbium and used by steel makers as grain refiner in HSLA steels and as a carbide former in austenitic stainless steels. FERRO PHOSPHORUS Melting Range -1250-1350°C SPECIFIC GRAVITY -6.4 Used in the production of phosphoric irons and certain free cutting steels, supplied in lumpy or crushed form, typically 25% P with controlled Si contents 1% and 2% max. FERRO SELENIUM Melting Range- 480-940°C SPECIFIC GRAVITY - 6.35 Available as the 50/50 alloy, normally in the lumpy or crushed form. Used in the production of free cutting stainless steel.

18. FERRO SILICON ZIRCONIUM Melting Range -1250-1340°C SPECIFIC GRAVITY -3.5 Typical analysis is 50% Si, 35% Zr . Used as deoxidant in steel castings or in certain steels where a low residual aluminium is required. FERRO TUNGSTEN Melting Range - 1650-2100°C SPECIFIC GRAVITY - 15.4 This alloy is mainly used in high speed and tool steels. Owing to its high melting point the alloy is almost always added to the furnace rather than to the ladle.

19. Applications of Ferro alloy The main applications of ferroalloys occur in the steelmaking process. They are added to steel to improve properties like strength, ductility, and fatigue or corrosion resistance.

20. FUTURE OUTLOOK FOR THE FERROALLOYS INDUSTRY The increasing demand for ferroalloys across the global steel industries, the automotive and transportation industries are expected to boost global market demand. The global ferroalloys market is expanding due to its use in the automotive, transportation industries and vehicle as well as technological advancements.

21. CONCLUSION Ferroalloys development and production have been boosted together with the rapid increase in steel and alloys processing. It soon became very clear that ferroalloys require new techniques as the then existing blast furnace or steelmaking converter technologies were not capable of fulfilling the demanding needs of industry. As the requisite electrical technology was developed in parallel, at the beginning of 20th century ferroalloys had caught up with electrometallurgy and this has continued until today.

22. References 1/ 1Rudolf Fichte. "Ferroalloys". Ullmann's Encyclopedia of Industrial Chemistry. Weinheim : Wiley-VCH. doi:10.1002/14356007. 2/ Corathers , Lisa A.; et al. (October 2010). Ferroalloys (PDF). Minerals Yearbook 2008 (Report). Vol. I. U.S. Geological Survey. pp. 25.1–25.14. doi:10.3133/ mybvi . Retrieved 2019-10-18. 3/ Bedinger , George M.; Corathers , Lisa A.; et al. (October 2016). Ferroalloys (PDF). Minerals Yearbook 2014 (Report). Vol. I. U.S. Geological Survey. pp. 25.1–25.3. doi:10.3133/ mybvi . Retrieved 2019-10-18. 4/ Kudo , Akira. Japanese-German Business Relations: Co-operation and Rivalry in the Interwar. pp. 89–108. Archived from the original on 2014-10-20. Retrieved 2014-12-21 5/ Ferronickel – Properties, Applications". AZoM.com. August 21, 2013