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. Over the past 10 years or so, lean manufacturing has been receiving an increasing amount of attention as one source for productivity improvements and cost reductions in manufacturing. Therefore, the production of low carbon ferrochrome by this process is associated with considerable difficul. China ferrochrome market by manufacturers, regions. Kr101469679b1 low carbonferrochromium manufacturing. Innovation for the manufacturing process increase production reduce consumption thats your new added value k a t t e c h n o l o g y f e r r o c h r o m e ferrochrome and kat technology do more do better the ferrochrome alloy is essential for the production of stainless steel and. Oct 15, 2019 the proposed project noront resources is planning to build a ferrochrome production facility fpf in northern ontario. And removing the slag produced by the thermite reaction. Keywords ferrochrome production, ferroalloy process optimization, chrome ore i. Effect of south africa chrome ores on ferrochrome production. Pdf exergy and its efficiency calculations in ferrochrome. However, during the cocktailing step, process temperatures are extremely high, resulting in rapid deterioration of the ladle. Low carbon ferro chrome can be obtained by reduction of chromite using silicon as a reducer in the form of silicochrome.
Electric power is generally used to supply the energy required to carry out the heating, melting and reduction reactions. With a sharp increase in electricity cost, all ferrochrome producers in south africa are looking for any alternatives that can use less electricity. Zimbabwes major producers of ferrochrome cut back on production approx. What is the sensitivity analysispricevolume of low carbon ferrochrome manufacturing plant. In modern industries, one of the main ferrochrome uses is to produce stainless steel, as it imparts strength and durability. Jamshedpur, india abstract energy is in the form of sio and co offthe increasing costs of electric energy and continuous. It is the raw material for producing ferrochrome, mainly a mixture of iron and chromium, which is used as an alloying material in the process of manufacturing stainless steel murthy, tripathy. Increasing stainless steel production around the globe is the significant factor driving the market growth. Outotecs ferrochrome process consists of the smelting of high carbon ferrochrome in a closed and sealed submerged arc furnace, using mainly sintered pellets as raw material, preheating the furnace feed in a shaft kiln located above the furnace, cleaning the furnace gas in two venturi scrubbers and further in a co filter optional, and. Ferrochrome production is essentially a carbothermic reduction operation taking place at high temperatures. Introduction igh carbon ferrochrome hcfecr is produced by carbothermic reduction of chrome ore. Study of carbothermic reduction processes in manufacture. Most of the worlds ferrochrome is produced in south africa, kazakhstan and india, which have large domestic chromite resources. Cr ore, an oxide of chromium and iron, is reduced by coal and coke to form the ironchromium alloy.
Pdf a solid reduction process is described whereby chromite is reduced with the help of calcium chloride to produce ferrochrome alloy. Nov 12, 2017 south african journal of industrial engineering may 2010 vol 211. Effect of chrome ore quality on ferrochrome production efficiency. Low carbon ferrochrome production lc fecr low carbon ferrochrome is a ferroalloy used to regulate the ratio of chromium in steel production without carbon and other unwanted ingredients. An alternative to this process is to remelt highcarbon ferrochromium with silica and coke. Chromite is a mineral and can be described as an iron chromium oxide, with a chemical formula of fecr 2 o 4. What are the projected payback period and irr of low carbon ferrochrome manufacturing plant. Jan 01, 2015 process for the manufacture of ferrochrome alloy comprising the steps of providing a pelletising feed, wherein the pelletising feed comprises chromite ore and silicon carbide as the only carbonaceous. 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.
Efficiency of the ferrochrome process type and preconditioning of the feed materials, preheating and prereduction. Effect of chrome ore quality on ferrochrome production. In the pure state it is resistant to ordinary corrosion, resulting in its application as an electroplated. Hailed by its proponents as a breakthrough means to analyze and improve pro. A good example of process optimization is the semiempirical model developed by broekman and ford1, which incorporated the. Due to high quality it is a reliable and economical alternative instead of. The saf process for ferrochrome production is extremely. The complete book on ferroalloys ferro manganese, ferro.
Jan 14, 2017 a vacuum process and manufacturing facilities for the production of lowcarbon ferrochrome are described. Ferrochrome fecr is a corrosionresistant alloy of chrome and iron containing between 50% and 70% chrome. Igh carbon ferrochrome hcfecr is produced by carbothermic reduction of chrome ore. Electronic pdf the global ferrochrome market size is anticipated to reach usd 28. 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.
Export prices for ferrochrome fell by 68% for the ten months to may 2009, as demand for ferrochrome from stainless steel mills collapsed. China ferrochrome market by manufacturers, regions province. What is the process flow sheet diagram of low carbon ferrochrome manufacturing project. This market research report provides information about reagents, country overview chemicals, chemicals industry.
Kr101469679b1 low carbonferrochromium manufacturing method. The market is mainly driven by demand from booming stainless steel industry especially in asia. Ferrochrome smelting slag slow cooled from the furnace showing the precipitation of. The conventional process for producing high carbon ferrochromium by. Ferrochrome production for metallurgical applications uses up more than 90% of the worlds chromite output of about 19 m tonnesy. Chromite lump ore, chrome ore briquettes, coke, quartz are mixed in a precalculated proportion.
Pdf direct production of ferrochrome by segregation reduction. Chrome ore is essential for the production of ferrochrome. Granulated slag samples were collected when the industry adopted water cooled slag granulation process. 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. On may 7, 2019, it was announced that the company selected sault ste. Duplex process for production of low carbon ferrochrome. The global low ferrochrome market is growing significantly in the. Manufacturing plant, detailed project report, profile. Study of carbothermic reduction processes in manufacture of. A vacuum process and manufacturing facilities for the production of low carbon ferro chrome are. Low carbon ferrochrome is a primary alloying element in the production of stainless steel. The low carbon content in ferrochrome silicon is a consequence of a decreased solubility of carbon due to the increase in silicon content. A ferrochrome manufacturing process is mostly conducted by the carbothermic reduction of chromite in an electric submerged arc furnace saf. Process for the manufacture of ferrochrome outotec oyj.
Most of the worlds ferrochrome is produced in south africa, kazakhstan and india, which have large domestic. 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. The production process is energy intensive, and consumes approximately 3,3003,800 kwh per ton of metal produced. 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. Process for the manufacture of ferrochrome outotec.
This market research report provides information about specialty chemicals, country overview chemicals, chemicals industry. Chromium cr is a brilliant, hard, refractory metal that melts at 1,857 c 3,375 f and boils at 2,672 c 4,842 f. Chromium processing, preparation of the ore for use in various products. The complete book on ferroalloys ferro manganese, ferro molybdenum, ferro niobium, ferro boron, ferro titanium, ferro tungsten, ferro silicon, ferro nickel, ferro chrome an alloy is a mixture or solid solution composed of metals. The ferrochrome alloy is produced via reduction of chromite ore to an alloy of chrome and iron. The global ferrochrome market size was valued at usd 16. The trends towards i utilization of medium grade ore fines by. In response to weakening demand and falling prices, major producers of ferrochrome, zimbabwes producers included, cut production, in some cases ceasing operations all together. An investigation of the effect of various chrome ores on the. Granulated slag samples were collected when the industry. System optimization and installation of gore filter bags resulted in improvements to the baghouse and overall production process. Power shortages coupled with high electricity tariffs over the past few years in south africa have adversely affected the ferrochrome production and has led to either shut down or acquisition of many. Locating and estimating air emissions from sources of chromium u. Agglomeration plants sinter, pelletisers, briquetting etc enable ferrochrome smelting in zimbabwe the consumption of chromite ore fines and concentrates sintering.
Keywordsferrochrome production, ferroalloy process optimization. The production of steel is the largest consumer of ferrochrome, especially the production of stainless steel with chromium content of 10 to 20% is the main application of ferrochrome. This is a twostage process and economically less attractive than the direct smelting process. Optimization of process parameter for smelting and reduction of ferrochrome. Ferrochrome production is a high energy intensive process consuming around 3000 to 3500 kwht of electrical energy. Though globally south africa is the largest producer of chrome ore and ferrochrome, one of the major issues that south africa faces is the availability of power. 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. Similarly, ferroalloys are the mixture of iron with. 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.
Throughout the years the economic optimization of industrial processes has developed into a respected enterprise based on the costeffectiveness of the specific process route. Optimization of process parameter for smelting and. Mixing molten chrome ore powder with a reducing agent powder containing no carbon to produce molten ferrochrome melted by a thermite reaction. The main reactions involved in the reduction of iron, chromium and silicon to the metal phase are briefly presented below subscripts x and y. The proposed project noront resources is planning to build a ferrochrome production facility fpf in northern ontario. The low carbon ferrochrome is being produced in the world by various processes, namely. 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. Pdf ferrochrome production is a high energy intensive process consuming around 3000 to 3500 kwht of electrical energy. Ferrochrome fecr is added to stainless steel to enhance its appearance and impart corrosion resistance. Production, characteristics and use of ferrochromium slags 173 2. Ferrochrome is produced by smelting of different grades of chromite ore with. A vacuum process and manufacturing facilities for the production of lowcarbon ferrochrome are described.
Ferroalloy is used to physically introduce or carry that element into molten metal, usually during steel manufacture. The mixing method perrin and duplex processes are most commonly used for the production thereof. Carbothermic process of reduction and temperature intervals of softening for chromiumdeficient ore materials was studied under laboratory conditions and comparison of domestic chromiumpoor raw and rich ore of kempirsaysk massif was made in an industrial situation. Due to high quality it is a reliable and economical alternative instead of metallic chromium in superalloy production. The duplex process for the production of low carbon ferro chrome has been highlighted and its advantage over. It could therefore be used as a tool to aid in managerial decisionmaking. Evaluation of the furnace method for the production of low. S environmental protection agency office of air and radiation office of air quality planning and standards research triangle park, north carolina, nc 27711. Manganese industry in india, ferro silicon production process, ferro chrome alloy manufacturing plant, ferro chrome manufacture, ferrochrome production plant, manufacturing business of ferrochrome, noble ferro alloys production, manufacturing of noble ferro alloys, how to start manufacturing business of noble. Process for the manufacture of ferrochrome alloy comprising the steps of providing a pelletising feed, wherein the pelletising feed comprises chromite ore and silicon carbide as the only carbonaceous material and the only reducing agent.
Stainless steel industry accounts for roughly more than 75%. Moving forward, key steps include environmental and feasibility assessments, along with community consultation and engagement. The vacuum process is based on the solidstate reaction between the carbon in finelyground, highcarbon ferrochrome and oxygenbearing materials to evolve carbon monoxide. South african journal of industrial engineering may 2010 vol 211. Ferrochrome production accounts for more than 95 percent. Major challenge faced by the south african manufacturers is lack of power supply as ferrochrome manufacturing is an energy intensive process. Ferrochrome is produced by electric arc carbothermic reduction of chromite. 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. Exergy and its efficiency calculations in ferrochrome. China ferrochrome market by manufacturers, regions province, type and application, forecast to 2022 report is published on june, 2017 and has 119 pages in it.
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