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V I Zhuchkov - One of the best experts on this subject based on the ideXlab platform.
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Ferroalloy Production Using Russian Crude Ore
Steel in Translation, 2020Co-Authors: V I Zhuchkov, L. I. Leont’ev, O. V. ZayakinAbstract:The key problem of ferroalloy production in Russia is the availability of crude ore. Only few types of alloys are produced at domestic plants from domestically-produced raw materials (ferrosilicon, vanadium alloys). The bulk of Ferroalloys is either imported from abroad or smelted from imported raw materials. The development of ferroalloy production is a challenging situation for Russia: raw material import addiction in the presence of large domestic mineral and raw material base, but substandard in terms of world standards quality. One of the main reasons for this situation (in addition to organizational and financial ones) is a well-established conservative approach to the ferroalloy smelting technology using the same type of crude ore and obtaining products as per GOST Standard. Domestic ferroalloy raw materials, as a rule, are of low quality. They have a low content of main elements (manganese, chromium ores), a high content of phosphorus (manganese, niobium ores), and sulfur (manganese ores). This requires physical and chemical studies and the development of new alternative technologies. It is possible to create new technology processes and different ferroalloy combinations that are not inferior in terms of their technical and economic indicators to products obtained from imported non-traditional domestic ore crude, based on deep physical, chemical and technological studies. For solving the domestic crude ore problem found in the ferroalloy industry, it is necessary for scientists, geologists, processing experts and metal-makers to work together.
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Structure and Properties of Nitrided Ferroalloys
Russian Metallurgy (Metally), 2020Co-Authors: L A Smirnov, A. S. Oryshchenko, O Vadimovich Zayakin, V I Zhuchkov, G. Yu. KalininAbstract:The structure and the physicochemical properties of nitrided chromium- and manganese-based Ferroalloys have been studied experimentally. Nitrogen in the alloys is shown to be mainly in the form of nitrides Mn_2N, CrN, and Cr_2N, the fractions of which are dependent on the nitrogen content and the methods of alloy manufacture. The liquidus temperature of the nitrided chromium-bearing Ferroalloys is lower than that of analogous nitrogen-free Ferroalloys, which positively influences the rate and degree of assimilation of elements by steel. The introduction of 8–16% nitrogen in the ferroalloy compositions decreases their real densities, which enables one to produce alloys with the optimal density. The apparent densities of the nitrided chromium and manganese Ferroalloys are very low (3000–4200 kg/m^3) due to their high porosity; as a result, they will be melted at the steel melt surface and will have a low degree of nitrogen assimilation. Higher degrees of nitrogen assimilation can be achieved as powdered alloys are injected in a gaseous nitrogen jet. The degree of transition of nitrogen to steel from the Ferroalloys is 47–84%; it is mainly dependent on the holding time of a nitrided steel in liquid state, the physicochemical characteristics of nitrided Ferroalloys, the composition of an alloyed metal, and the types and content of nitride-forming elements (Cr, Mn, Ti, etc.) in it. The highest degree of transition of nitrogen to steel (84%) was reached using an as-cast nitrided chromium sample with 8% N in the first minute of holding. Further holding up to 30 min of the liquid sample at 1500°C leads to a decrease in the degree of nitrogen assimilation to 52%.
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Mathematical Simulation of the Melting of Nitrided Ferroalloys in an Iron–Carbon Melt
Russian Metallurgy (Metally), 2019Co-Authors: O Vadimovich Zayakin, L A Smirnov, V I Zhuchkov, E. Yu. LozovayaAbstract:The melting of nitrided Cr–N–Fe–Si–Al Ferroalloys in an iron–carbon melt under static conditions is studied by mathematical simulation. The influence of the initial ferroalloy lump sizes, the chromium content in ferroalloy, and the iron–carbon melt temperature on the alloy melting time is determined. The introduction of 12% chromium into the composition of a low-carbon FKh010 ferrochrome is shown to decrease the temperature of the end of solidification of the ferroalloy, and it passes from the group of high-melting to the group of low-melting alloys. As a result, the mechanism of melting the ferroalloy in an iron–carbon melt changes, and the time of its melting in steel decreases, especially at low temperatures (1540–1560°C). An increase in the chromium content from 61 to 74% at 12–16% N in the alloys under study transfer them from low-melting to high-melting ones, which is accompanied by a sharp increase in the time of melting the Ferroalloys in an iron–carbon melt. The temperature of the steel to be processed significantly affects the ferroalloy melting time. The sharp decrease in the total melting time of FKhN20 and FKh010 alloys induced by an increase in the iron–carbon melt temperature from 1540 to 1560°C is caused by the transition of these Ferroalloys from ultrahigh-melting to high-melting alloys. The lump sizes in the nitrided Ferroalloys are found to affect their melting time: when the lump size increases eightfold (from 6 to 50 mm), the frozen solid steel skin thickness increases by a factor of 5–6 and the total melting time increases by a factor of 30. A nitrided FKhN10 ferroalloy has the best characteristics for processing steel due to its low melting point and the shortest melting time in an iron–carbon melt, which facilitates the assimilation of alloying elements by steel.
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Manufacturing and Application of Complex Ferroalloys
KnE Materials Science, 2019Co-Authors: V I Zhuchkov, O Vadimovich ZayakinAbstract:The tightening of requirements for the quality of steel, a change in the composition of raw materials requires the release of more efficient Ferroalloys of the new generation, suitable for progressive steel production processes. Such products include complex Ferroalloys containing, in addition to iron, two or more functional elements. Complex Ferroalloys should be created in the most favorable combination of components, contributing to the necessary effective impact on the quality of the metal being processed, with a high degree of assimilation of useful elements in it. Changes in the characteristics of complex ferroalloy, affecting the assimilation of target (basic) elements, should be carried out by regulating the composition and ratio of elements that can be included in almost any ferroalloy, since they are part of all steels and cast irons or they’re required by the conditions of their smelting. Firstly, these elements should include silicon and manganese. Silicon can reduce the melting temperature, density, and melting time of ferroalloy in the liquid metal. For example, the addition of 1% silicon to low-carbon ferrochrome can reduce the melting point of the alloy by 8–9 degrees. Compositions of new complex Ferroalloys of systems Fe-Si-Ca-Ba, Fe-Si-B, Fe-Si-Al-Nb, Fe-Si-Mn-V have been successfully tested and introduced into production. Keywords: metallurgy, ferroalloy, melting, density, physical and chemical properties, steel
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Situation and Development of Ferroalloy Metallurgy in Russia
KnE Materials Science, 2019Co-Authors: V I Zhuchkov, L Igorevich Leontiev, V Yakovlevich DashevskyAbstract:Ferroalloy production is an important branch of metallurgy having a great impact on its development since the treatment of liquid metals by Ferroalloys remains one of the main methods to regulate the quality of steel, cast iron,and nonferrous alloys. Manganese is the most essential element to treat ferrous and non-ferrous metals. A need for manganese alloys in Russia averages to 600–650 metric tons per year, but only a half of the quantity is satisfied by the domestic production. In contrast to manganese alloys, Russia provides itself with chromium Ferroalloys obtained with the use of foreign raw materials. Domestic ores are used in limited quantities. Taking into account the strategic importance of ferroalloy industry and the necessity to create and include manganese and chromium ore bases, as well as the other basic problems, the achievement of the goals has to be implemented by enterprises with the help of the State. The output of ferrosilicon and crystal silicon in the Russian Federation exceeds its consumption in the country due to raw material reserves (quartzite, quartz), high productive capacity, and consumer demands. Ferroalloy enterprises in Russia produce ferrovanadium, ferromolybdenum, ferroniobium, ferrotungsten, ferrotitanium, and ferronickel. A traditional challenge for ferroalloy enterprises in Russia is improving the competitiveness at the expense of reducing production costs, improving the production quality, and solving the issue of import substitution for certain types of Ferroalloys. Keywords: Ferroalloys, manganese, ferrochromium, production
L. I. Leont’ev - One of the best experts on this subject based on the ideXlab platform.
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Ferroalloy Production Using Russian Crude Ore
Steel in Translation, 2020Co-Authors: V I Zhuchkov, L. I. Leont’ev, O. V. ZayakinAbstract:The key problem of ferroalloy production in Russia is the availability of crude ore. Only few types of alloys are produced at domestic plants from domestically-produced raw materials (ferrosilicon, vanadium alloys). The bulk of Ferroalloys is either imported from abroad or smelted from imported raw materials. The development of ferroalloy production is a challenging situation for Russia: raw material import addiction in the presence of large domestic mineral and raw material base, but substandard in terms of world standards quality. One of the main reasons for this situation (in addition to organizational and financial ones) is a well-established conservative approach to the ferroalloy smelting technology using the same type of crude ore and obtaining products as per GOST Standard. Domestic ferroalloy raw materials, as a rule, are of low quality. They have a low content of main elements (manganese, chromium ores), a high content of phosphorus (manganese, niobium ores), and sulfur (manganese ores). This requires physical and chemical studies and the development of new alternative technologies. It is possible to create new technology processes and different ferroalloy combinations that are not inferior in terms of their technical and economic indicators to products obtained from imported non-traditional domestic ore crude, based on deep physical, chemical and technological studies. For solving the domestic crude ore problem found in the ferroalloy industry, it is necessary for scientists, geologists, processing experts and metal-makers to work together.
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Improved manganese extraction in the production of manganese Ferroalloys
Steel in Translation, 2017Co-Authors: V. Ya. Dashevskii, A. A. Aleksandrov, Alexander V. Zhdanov, V I Zhuchkov, L. I. Leont’evAbstract:In the production of manganese Ferroalloys from ore, about 50% of the manganese in the ore is lost. The manganese lost with the enrichment-slag tailings may be returned to the production of manganese Ferroalloys by dithionate method of enrichment of the slurries. A technology is developed for the production of high-carbon ferromanganese from concentrate obtained by the chemical enrichment of tailings slurries. Low-phosphorus Mn slag is used in the production of ferrosilicomanganese and refined manganese Ferroalloys. A method is described for alloying hot metal with manganese from slag during the production of lowand medium-carbon ferromanganese. Processes are developed for the production of medium-carbon ferromanganese by mixing ore–limestone melt with high-carbon ferromanganese and removing the phosphorus from Mn-bearing melts by bubbling with CO. The degree of phosphorus removal (70–90%) depends on the bubbling time. By means of improved production of manganese Ferroalloys and extraction of manganese from slag and slurries, the manganese extraction may be significantly increased.
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Physicochemical characteristics, production and application of boron-bearing complex Ferroalloys
Steel in Translation, 2017Co-Authors: V I Zhuchkov, O Vadimovich Zayakin, L. I. Leont’ev, A. V. Sychev, I. N. Kel’Abstract:The expediency of producing and using complex Ferroalloys in steelmaking is analyzed in terms the manufacturing technology, the raw materials employed, and the interactions of the Ferroalloys with the molten steel. The need to produce complex Ferroalloys with boron is established. The fundamental principles for determining the best composition of such alloys are presented. The basic compositions of complex Ferroalloys with boron (ferrosilicomanganese with boron, ferrosilicon with boron, ferrosilicomanganese with boron and chromium) are established by studying the physicochemical properties of alloys and their interactions with the steel melt. If the characteristics (melting point, density, melting time of the ferroalloy in liquid steel, etc.) of complex Ferroalloys with boron are compared with those of ferroboron, which is widely used, the complex alloys have clear benefits. The composition of the complex Ferroalloys with boron includes active elements (Si, Al, Ti) facilitating the binding of oxygen and nitrogen from the steel melt in strong compounds and hence preventing their reaction with boron. The recommended boron content in the ferroalloy is 0.7–2%. That permits increase in the quantity of complex Ferroalloys with boron in the steel and hence increase in the reliability and stability of boron assimilation. At elevated temperatures (1430–1570°C), the oxidation of ferrosilicoboron is 4–7 times less than that of ferroboron. Data are presented regarding the industrial production and use of ferrosilicoboron in the steel-smelting shop. The boron assimilation from complex alloys in microalloying of the steel is studied. The use of ferrosilicoboron does not require significant changes in the existing system for reduction by ferrosilicon; the boron assimilation is 77.8–96.3% (mean 86.6%). With a boron concentration of 0.0021–0.0027% in the steel during ladle treatment, its content in the cast metal will be no less than 0.0020%. If boron is introduced in steel by means of ferrosilicomanganese with boron, the boron assimilation is increased by a factor of 1.6 (from 48 to 77%, on average) in comparison with the use of ferroboron.
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Status and Prospects of Ferroalloys Production in the Russian Federation
Metallurgist, 2016Co-Authors: L. I. Leont’ev, V. Ya. Dashevskii, L A Smirnov, V I Zhuchkov, A. V. Zhdanov, S. A. GurovaAbstract:Data are presented on the production and consumption of Ferroalloys in the Russian Federation from 1994 to 2014. The quantities of the main Ferroalloys that were made during this period are compared to the volume of steel production, and a comparison is also made between the structure of Ferroalloys production in Russia and abroad. Data on the import, export, and apparent consumption of Ferroalloys ate also reported. It is noted that Russia needs to expand its raw-materials base in order to make the main Ferroalloys: manganese-, chromium-, and silicon-based Ferroalloys. Such expansion is necessary to ensure that Russian companies can compete in the international market and that Russia is not threatened economically. These goals can be accomplished only with the support of the government.
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Ferroalloy Production in Russia
Steel in Translation, 2015Co-Authors: L. I. Leont’ev, V I Zhuchkov, A. V. Zhdanov, V. Ya. DashevskiiAbstract:Russian production and demand for Ferroalloys are considered. The main ferroalloy producers are noted. The volume of imports and exports and the apparent demand for the main Russian Ferroalloys between 1990 and 2014 are detailed. The change in the structure of ferroalloy production, globally and in Russia, is outlined. Priorities for the Russian ferroalloy industry in order to improve global and domestic competitiveness are recommended.
A. V. Zhdanov - One of the best experts on this subject based on the ideXlab platform.
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Waste Generation and Recycling in the Ferroalloy Industry
Advanced Methods and Technologies in Metallurgy in Russia, 2017Co-Authors: A. V. Zhdanov, V I Zhuchkov, V. Y. Dashevskiy, L. I. LeontyevAbstract:Generation of technogeneous waste in production of Ferroalloys and possible solutions for recycling are presented in the article. A lot of by-products are generated at the stage of ferroalloy production: slags, raw materials and ferroalloy fines, sludge, dusts and some other materials. Chemical composition and quantities of slags, dusts and sludge in production of manganese, chromium and silicon alloys are given. Ferroalloy production waste can be recycled in ferroalloy production process or allied production chains. Possible applications of technogeneous raw materials in ferroalloy and allied production technologies are considered. Involvement of ferroalloy production waste into ferroalloy production technology requires deliberate decisions, as performance characteristics of furnaces in ferroalloy production depend on quality of raw materials (manganese ores, chromites, etc.). It is proposed to find a recycling solution on the basis of precise estimation of physic-chemical characteristics of materials.
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Status and Prospects of Ferroalloys Production in the Russian Federation
Metallurgist, 2016Co-Authors: L. I. Leont’ev, V. Ya. Dashevskii, L A Smirnov, V I Zhuchkov, A. V. Zhdanov, S. A. GurovaAbstract:Data are presented on the production and consumption of Ferroalloys in the Russian Federation from 1994 to 2014. The quantities of the main Ferroalloys that were made during this period are compared to the volume of steel production, and a comparison is also made between the structure of Ferroalloys production in Russia and abroad. Data on the import, export, and apparent consumption of Ferroalloys ate also reported. It is noted that Russia needs to expand its raw-materials base in order to make the main Ferroalloys: manganese-, chromium-, and silicon-based Ferroalloys. Such expansion is necessary to ensure that Russian companies can compete in the international market and that Russia is not threatened economically. These goals can be accomplished only with the support of the government.
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Ferroalloy Production in Russia
Steel in Translation, 2015Co-Authors: L. I. Leont’ev, V I Zhuchkov, A. V. Zhdanov, V. Ya. DashevskiiAbstract:Russian production and demand for Ferroalloys are considered. The main ferroalloy producers are noted. The volume of imports and exports and the apparent demand for the main Russian Ferroalloys between 1990 and 2014 are detailed. The change in the structure of ferroalloy production, globally and in Russia, is outlined. Priorities for the Russian ferroalloy industry in order to improve global and domestic competitiveness are recommended.
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Problems with Waste Generation and Recycling in the Ferroalloys Industry
Metallurgist, 2015Co-Authors: A. V. Zhdanov, V. Ya. Dashevskii, V I Zhuchkov, L. I. Leont’evAbstract:The wastes generated in the production of Ferroalloys are mainly in the form of slag, dust, and sludge from gas-cleaning systems, in addition to ferroalloy gas. The volumes of these waste products that are formed depend on the charge materials and manufacturing technology used at the given factory. The problem of waste formation during Ferroalloys production should be regarded as a direct result of the technology chosen for the production process. Efficient resolution of the waste-recycling problem requires maximal collection and disposal of the wastes and analysis of alternative uses for them based on an accurate assessment of their physicochemical characteristics (their chemical, fractional, and mineralogical compositions, in addition to several other characteristics).
V. Ya. Dashevskii - One of the best experts on this subject based on the ideXlab platform.
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Improved manganese extraction in the production of manganese Ferroalloys
Steel in Translation, 2017Co-Authors: V. Ya. Dashevskii, A. A. Aleksandrov, Alexander V. Zhdanov, V I Zhuchkov, L. I. Leont’evAbstract:In the production of manganese Ferroalloys from ore, about 50% of the manganese in the ore is lost. The manganese lost with the enrichment-slag tailings may be returned to the production of manganese Ferroalloys by dithionate method of enrichment of the slurries. A technology is developed for the production of high-carbon ferromanganese from concentrate obtained by the chemical enrichment of tailings slurries. Low-phosphorus Mn slag is used in the production of ferrosilicomanganese and refined manganese Ferroalloys. A method is described for alloying hot metal with manganese from slag during the production of lowand medium-carbon ferromanganese. Processes are developed for the production of medium-carbon ferromanganese by mixing ore–limestone melt with high-carbon ferromanganese and removing the phosphorus from Mn-bearing melts by bubbling with CO. The degree of phosphorus removal (70–90%) depends on the bubbling time. By means of improved production of manganese Ferroalloys and extraction of manganese from slag and slurries, the manganese extraction may be significantly increased.
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Status and Prospects of Ferroalloys Production in the Russian Federation
Metallurgist, 2016Co-Authors: L. I. Leont’ev, V. Ya. Dashevskii, L A Smirnov, V I Zhuchkov, A. V. Zhdanov, S. A. GurovaAbstract:Data are presented on the production and consumption of Ferroalloys in the Russian Federation from 1994 to 2014. The quantities of the main Ferroalloys that were made during this period are compared to the volume of steel production, and a comparison is also made between the structure of Ferroalloys production in Russia and abroad. Data on the import, export, and apparent consumption of Ferroalloys ate also reported. It is noted that Russia needs to expand its raw-materials base in order to make the main Ferroalloys: manganese-, chromium-, and silicon-based Ferroalloys. Such expansion is necessary to ensure that Russian companies can compete in the international market and that Russia is not threatened economically. These goals can be accomplished only with the support of the government.
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Ferroalloy Production in Russia
Steel in Translation, 2015Co-Authors: L. I. Leont’ev, V I Zhuchkov, A. V. Zhdanov, V. Ya. DashevskiiAbstract:Russian production and demand for Ferroalloys are considered. The main ferroalloy producers are noted. The volume of imports and exports and the apparent demand for the main Russian Ferroalloys between 1990 and 2014 are detailed. The change in the structure of ferroalloy production, globally and in Russia, is outlined. Priorities for the Russian ferroalloy industry in order to improve global and domestic competitiveness are recommended.
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Problems with Waste Generation and Recycling in the Ferroalloys Industry
Metallurgist, 2015Co-Authors: A. V. Zhdanov, V. Ya. Dashevskii, V I Zhuchkov, L. I. Leont’evAbstract:The wastes generated in the production of Ferroalloys are mainly in the form of slag, dust, and sludge from gas-cleaning systems, in addition to ferroalloy gas. The volumes of these waste products that are formed depend on the charge materials and manufacturing technology used at the given factory. The problem of waste formation during Ferroalloys production should be regarded as a direct result of the technology chosen for the production process. Efficient resolution of the waste-recycling problem requires maximal collection and disposal of the wastes and analysis of alternative uses for them based on an accurate assessment of their physicochemical characteristics (their chemical, fractional, and mineralogical compositions, in addition to several other characteristics).
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Manganese-ferroalloy production from Russian manganese ore
Steel in Translation, 2014Co-Authors: L. A. Polulyakh, V. Ya. Dashevskii, Yu. S. YusfinAbstract:Optimal technology for the production of manganese Ferroalloys from Usinsk magnesium ore is developed. To that end, the chemical composition and the concentrates and the characteristics of ferroalloy smelting are analyzed. The proposed technology permits the production of standard manganese Ferroalloys, without the need for imported manganese ores that are rich in manganese and low in phosphorus. The proposed technology is of strategic value in terms of national economic security and import substitution. Finally, attention turns to the possibility of increasing Russian production of high-carbon ferromanganese and ferrosilicomanganese on the basis of Russian manganese ore and developing production technologies for refined manganese Ferroalloys (moderate- and low-carbon ferromanganese and metallic manganese) without reliance on imported ores.
Michael Gasik - One of the best experts on this subject based on the ideXlab platform.
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Theory of Ferroalloys Processing
Handbook of Ferroalloys, 2013Co-Authors: Heikki Jalkanen, Michael GasikAbstract:Abstract The metallurgical processing of Ferroalloys is based on a coherent combination of many scientific fields, which are briefly outlined in this chapter. The metal’s recovery process is based on reduction reactions, where metallurgical thermodynamics and kinetics are of a paramount importance. This includes the knowledge and ability to calculate, monitor, and change the formation of solutions and phases, rate of the reactions, and handling of reaction products in the most efficient way. In parallel, theoretical and engineering data on heat, mass, momentum, and charge transfer are critical for the development and design of ferroalloy production processes and furnaces. The chapter also discusses the basics of the structure and properties of metal and oxide (slag) when melted together with carbon reductants.
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Technology of Ferroalloys with Alkaline-Earth Metals
Handbook of Ferroalloys, 2013Co-Authors: Michael GasikAbstract:This chapter deals with alkaline-earth metals (Mg, Ca, Sr, Ba) and their Ferroalloys technology. The chapter provides an overview of these metals, their properties, and their reactions with other elements, and it outlines major relevant phase equilibria diagrams. Oxide systems equilibria are also considered. Different raw materials and methods for producing alkaline-earth Ferroalloys and master alloys are presented. Specific details of the technology for smelting are described depending on the alloy type and grade. Additionally, the theory and technology used to produce calcium carbide and oxide (metallurgical lime) are described.
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Handbook of Ferroalloys : Theory and Technology
2013Co-Authors: Michael GasikAbstract:This handbook gathers, reviews and concisely presents the core principles and varied technology involved in processing Ferroalloys. Background content in thermodynamics, kinetics, heat and mass transfer is accompanied by an overview of electrical furnaces theory and practice as well as sustainability issues. The work includes detailed coverage of the major technologies of ferrosilicon, ferronickel, ferromolybdenum, ferrotungsten, ferrovanadium, ferromanganese and lesser known minor Ferroalloys. Distilling the results of many years' experience in Ferroalloys, Michael Gasik has assembled contributions from the worlds' foremost experts. The work is therefore a unique source for scientists, engineers and university students, exploring in depth an area which is one of the most versatile and increasingly used fields within modern metallurgy. All-in-one source for the major Ferroalloys and their metallurgical processing technologies, cutting research time otherwise spent digging through old handbooks or review articles. In-depth discussion of the C, Si, Al-reduction, groups II-VIII of the periodic table, supporting analysis of metallurgical processing. Contemporary coverage includes environment and energy saving issues.