Casting of Ferroalloys

Casting of ferroalloys is a part of the production process that has been somewhat outdated compared to the preceding reduction and refining processing part of the manufacturing process.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.