Casting of ferroalloys is a part of the production process that has been somewhat outdated compared to the preceding reduction and refining processing part of the manufacturing process. Layer casting and chill mold casting have been the dominant types of casting processes even if casting on cast iron plates, water-cooled copper and granulation has gained a certain, but moderate volume. Elkem took the initiative to explore a Direct Strip Casting (DSC) type of process. Measurements of heat transfer rates related to different substrate materials, introductory laboratory scale casting in order of studying material structures and properties, and full-scale experimental casting of 65 % FeSi alloy was performed. One main reason for changing the casting process is the environmental issue. The DSC method seems also to represent an economic advantage over traditional methods.
{"title":"Casting of Ferroalloys","authors":"Karl R. Forwald","doi":"10.2139/ssrn.3930043","DOIUrl":"https://doi.org/10.2139/ssrn.3930043","url":null,"abstract":"Casting of ferroalloys is a part of the production process that has been somewhat outdated compared to the preceding reduction and refining processing part of the manufacturing process. Layer casting and chill mold casting have been the dominant types of casting processes even if casting on cast iron plates, water-cooled copper and granulation has gained a certain, but moderate volume. Elkem took the initiative to explore a Direct Strip Casting (DSC) type of process. Measurements of heat transfer rates related to different substrate materials, introductory laboratory scale casting in order of studying material structures and properties, and full-scale experimental casting of 65 % FeSi alloy was performed. One main reason for changing the casting process is the environmental issue. The DSC method seems also to represent an economic advantage over traditional methods.","PeriodicalId":313766,"journal":{"name":"INFACON XVI 2021: Si/FeSi","volume":"74 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122457369","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
B. Machulec, Jerzy Przegedza, L. Banasik, S. Kozłowski
The permanent control and continuous improvement of the ferrosilicon smelting process in the submerged-arc furnace is the primary task of the technological services and process management. This has a significant impact on the economic performance and competitiveness of the plant. This requires a precise definition and specification of all input and output components that affect the process technical and economic indicators. This procedure should be based on the identification of appropriately grouped components under the popular 6M principle (Man, Machine, Material, Method, Measurement, Management) presented in the form of Ishikawa cause and effect diagram. It is also useful to improve the process by the method of "small steps" in which employees of all levels participate (Kaizen method). The basic tool for improvement is statistical process control (SPC). The task of the SPC is to monitor parameters that are important for the physicochemical process and production results. Periodic material and energy balances of the process at discreet time intervals are also very useful. This allows us to monitor and provide information about the course of important parameters of the technological process and to respond quickly to irregularities.
{"title":"Permanent Control and Continuous Improvement of the Ferrosilicon Smelting Process","authors":"B. Machulec, Jerzy Przegedza, L. Banasik, S. Kozłowski","doi":"10.2139/ssrn.3930055","DOIUrl":"https://doi.org/10.2139/ssrn.3930055","url":null,"abstract":"The permanent control and continuous improvement of the ferrosilicon smelting process in the submerged-arc furnace is the primary task of the technological services and process management. This has a significant impact on the economic performance and competitiveness of the plant. This requires a precise definition and specification of all input and output components that affect the process technical and economic indicators. This procedure should be based on the identification of appropriately grouped components under the popular 6M principle (Man, Machine, Material, Method, Measurement, Management) presented in the form of Ishikawa cause and effect diagram. It is also useful to improve the process by the method of \"small steps\" in which employees of all levels participate (Kaizen method). The basic tool for improvement is statistical process control (SPC). The task of the SPC is to monitor parameters that are important for the physicochemical process and production results. Periodic material and energy balances of the process at discreet time intervals are also very useful. This allows us to monitor and provide information about the course of important parameters of the technological process and to respond quickly to irregularities.","PeriodicalId":313766,"journal":{"name":"INFACON XVI 2021: Si/FeSi","volume":"186 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"116392286","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Slag samples from five industrial Si furnaces and one FeSi furnace excavation have been investigated in this study. For one furnace, the slag close to the tapping canal was investigated more thoroughly. The furnace is divided into three main areas: higher up in the furnace, near the furnace bottom and samples from zones near the tapping canal. It is found that the slag mainly consists of different compositions of SiO2-CaO-Al2O3 and that the areas higher up in the furnaces generally contains more SiO2 than in the bottom. It is also found that the composition varies more in the higher parts of the furnaces. The second part of the study includes tapped slag from two of the Si furnaces. Slag have been collected from the tap-hole at Elkem Thamshavn regularly in a period of one year, and three slag samples are collected from Furnace B. It is found that the slag composition does not vary much over time, neither from day to day nor in monthly basis. It is also found that the tapped slag is a mix of the slag inside the furnace and is hence more affected by the accumulated furnace slag than the slag produced from the recently added raw materials.
本文对5座工业硅炉和1座稀土炉的矿渣样品进行了研究。对于某炉，对靠近出渣管的炉渣进行了较为彻底的研究。该炉被分为三个主要区域:炉内较高的区域，靠近炉底的区域和靠近出料管的区域的样品。结果表明，炉渣主要由SiO2- cao - al2o3的不同组分组成，炉体上部的SiO2含量普遍高于炉体底部。还发现，在炉子的较高部分，成分变化更大。研究的第二部分包括两个硅炉的出渣。在一年内定期从Elkem Thamshavn的出水口收集炉渣，并从b炉收集了三个炉渣样品。结果发现，炉渣成分随时间变化不大，无论是每天还是每月。还发现出渣是炉内渣的混合物，因此受堆积炉渣的影响比新加入原料产生的渣更大。
{"title":"SiO2-CaO-Al2O3 slags in Si/FeSi furnaces","authors":"M. Tangstad, M. Folstad","doi":"10.2139/ssrn.3922187","DOIUrl":"https://doi.org/10.2139/ssrn.3922187","url":null,"abstract":"Slag samples from five industrial Si furnaces and one FeSi furnace excavation have been investigated in this study. For one furnace, the slag close to the tapping canal was investigated more thoroughly. The furnace is divided into three main areas: higher up in the furnace, near the furnace bottom and samples from zones near the tapping canal. It is found that the slag mainly consists of different compositions of SiO2-CaO-Al2O3 and that the areas higher up in the furnaces generally contains more SiO2 than in the bottom. It is also found that the composition varies more in the higher parts of the furnaces. The second part of the study includes tapped slag from two of the Si furnaces. Slag have been collected from the tap-hole at Elkem Thamshavn regularly in a period of one year, and three slag samples are collected from Furnace B. It is found that the slag composition does not vary much over time, neither from day to day nor in monthly basis. It is also found that the tapped slag is a mix of the slag inside the furnace and is hence more affected by the accumulated furnace slag than the slag produced from the recently added raw materials.","PeriodicalId":313766,"journal":{"name":"INFACON XVI 2021: Si/FeSi","volume":"40 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124683314","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
The bulk resistivity of coal that has been partially transformed to silicon carbide (SiC) over the temperature range 25-1600°C was investigated with an emphasis on temperature, SiC content, bulk density, and presence of elemental silicon. The materials were 0%SiC (wt%), 30%SiC, 69%SiC, and 72%SiC. Only the 72%SiC sample contained elemental silicon in substantial amounts. At low temperatures, there is high variation among all the materials, but at high temperatures the differences are less severe, as the results are all the same magnitude. The difference of the materials with the highest and lowest resistivity was around 30 mΩm between the 30%SiC and the 69%SiC at 1500°C. The mechanical strength of the material is lowered upon conversion to SiC but is raised once elemental silicon begins to form. In addition to temperature, the resistivity seems to respond to SiC content, bulk density, and the presence of silicon. An increase in bulk density consistently leads to a decrease in the resistivity, except with the presence of silicon. SiC content may have some effect, but it is lesser compared to the other factors examined so far.
{"title":"Electrical Resistivity of Partially Transformed Silicon Carbide Made from Coal","authors":"M. Tangstad, Haley Hoover, G. Sævarsdóttir","doi":"10.2139/ssrn.3922184","DOIUrl":"https://doi.org/10.2139/ssrn.3922184","url":null,"abstract":"The bulk resistivity of coal that has been partially transformed to silicon carbide (SiC) over the temperature range 25-1600°C was investigated with an emphasis on temperature, SiC content, bulk density, and presence of elemental silicon. The materials were 0%SiC (wt%), 30%SiC, 69%SiC, and 72%SiC. Only the 72%SiC sample contained elemental silicon in substantial amounts. At low temperatures, there is high variation among all the materials, but at high temperatures the differences are less severe, as the results are all the same magnitude. The difference of the materials with the highest and lowest resistivity was around 30 mΩm between the 30%SiC and the 69%SiC at 1500°C. The mechanical strength of the material is lowered upon conversion to SiC but is raised once elemental silicon begins to form. In addition to temperature, the resistivity seems to respond to SiC content, bulk density, and the presence of silicon. An increase in bulk density consistently leads to a decrease in the resistivity, except with the presence of silicon. SiC content may have some effect, but it is lesser compared to the other factors examined so far.","PeriodicalId":313766,"journal":{"name":"INFACON XVI 2021: Si/FeSi","volume":"12 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133034086","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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