Theoretical and Experimental Substantiation for the Production of Siliceous Ferroalloy and Calcium Carbide from High-Silica Phosphorites
Shevko V. Adam T. Badikova A. Iskandirov M.
2025International Information and Engineering Technology Association
Mathematical Modelling of Engineering Problems
2025#12Issue 2709 - 718 pp.
Despite the large number of existing technologies for processing various phosphoritecontaining raw materials, there is practically no work on the independent processing of phosphatized flints in the phosphate industry (due to their low P2O5 content). This study aims to explore the possibility of processing high-silica phosphate rock from the Karatau basin to produce ferrosilicon and calcium carbide while simultaneously extracting phosphorus. The research involved thermodynamic modeling using HSC-10 Chemistry software and experimental smelting in an electric arc furnace. The article reports the results of studies on the processing of phosphatized flints from the Karatau basin with the production of ferrosilicon, calcium carbide, and phosphorus distillation. The findings demonstrate that the interaction of silicon and carbon with iron in equal proportions leads to the formation of iron silicides, calcium carbide, and gaseous phosphorus. The formation of ferrosilicon begins at 1200℃, calcium carbide appears at 1,600-1,700℃. FeSi25 grade ferrosilicon and calcium carbide in the amount of 100-200 dm3/kg were obtained at 1,789-2,000℃. Phosphorus is effectively extracted into the gas phase, with 75-79% of silicon extracted into the alloy and 59-61% of calcium into the calcium carbide. The slag-free electrothermal processing method increases raw material utilization efficiency from 43.75% to 79.92%, addressing significant environmental concerns associated with slag production in conventional methods. This research provides a sustainable pathway for utilizing phosphatized flints, contributing to resource optimization and reduced environmental impact.
Karatau basin , material processing , phosphatized flint , silicon , thermodynamic modeling
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Department of Technologies of silicate materials and metallurgy, Higher School of Chemical Engineering and Biotechnology, Mukhtar Auezov South Kazakhstan University, Shymkent, 160012, Kazakhstan
Department of Technologies of silicate materials and metallurgy
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