Resource-Efficient Smelting Technology for FeCrMnSi Ferroalloy Production from Technogenic Wastes in an Ore-Thermal Furnace
Makhambetov Y. Zhakan A. Zhunusov A. Kabylkanov S. Burumbayev A. Sadyk Z. Akhmetov A. Uakhitova B.
December 2025Multidisciplinary Digital Publishing Institute (MDPI)
Metals
2025#15Issue 12
The article presents the results of a study on the production of a complex chromium–manganese–silicon-containing ferroalloy in a large-scale laboratory ore-thermal furnace using man-made waste—chromium-containing aspiration dust obtained during smelting of high-carbon ferrochrome, fines (−5 mm) of iron–manganese ore currently stored in landfills, and finely dispersed coal sludge formed during enrichment. A single-stage technology for the production of a new complex chromium–manganese–silicon-containing ferroalloy by carbothermal reduction is proposed. A metallurgical assessment of the initial charge materials was carried out by the X-ray diffraction (XRD) phase analysis, and metal samples of the obtained ferroalloy were studied by scanning electron microscopy (SEM) in combination with energy dispersive spectroscopy (EDS). The resulting ferroalloy has a complex microstructure with a predominance of carbide and intermetallic phases. A high degree of extraction of chromium (up to 80%), manganese (up to 75%), and silicon (up to 35%) was recorded. The average chemical composition of the obtained ferroalloy, wt.%: Cr—37.41; Mn—17.31; Si—11.84; C—3.81; P—0.14; S—0.02. The slag formed during the smelting of the ferroalloy has satisfactory technological properties: it is characterized by good fluidity, and it actively exits the furnace by gravity. Entanglement of metal kings in the slag is not observed. The results obtained confirm the technological feasibility of the utilization of technogenic raw materials for the production of complex ferroalloys of the FeCrMnSi type.
basicity of slag , carbothermal reduction , chromium–manganese–silicon-containing ferroalloy , man-made waste , ore-thermal furnace , X-ray diffraction phase analysis
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Chemical-Metallurgical Institute Named After Zh. Abishev, Karaganda, 100030, Kazakhstan
Department of Metallurgy, Toraighyrov University, Pavlodar, 140008, Kazakhstan
Department of Metallurgy and Mining, K. Zhubanov Aktobe Regional University, Aktobe, 030000, Kazakhstan
Chemical-Metallurgical Institute Named After Zh. Abishev
Department of Metallurgy
Department of Metallurgy and Mining
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