Producing a siliceous ferroalloy from a mixture of amorphous rocks

The main silicon-containing component in a charge during ferrosilicon smelting is quartzite. The carbothermic reduction rate of the crystalline structure SiO2 has a limitation associated with a fixed energy reserve of silicon-oxygen bond. The reactive capacity of silica can be increased by using its amorphous form instead of the crystalline SiO2. The amorphous form of silica has a higher dispersion, greater free surface energy, and, consequently, a more active degree of entering into a reaction. Such silica-containing materials include amorphous rocks: diatomite, opoka, tripoli. The article presents the results of experimental studies of electrothermal ferrosilicon production from a mixture of amorphous rocks (tripoli, opoka, diatomite with a mass ratio of 1:1:1). It is established that when smelting the mixture of amorphous rocks containing 77 % SiO2, 7.9 % Al2O3, 5.2 % Σ CaO and MgO, 4 % Σ K2O Na2O, 3.3 % Fe2O3, 1.3 % CaCO3, 0.9 % CaSO4, 0.4 % others, three ferrosilicon grades are formed: FeSi25 (22–29 % Si), FeSi45 (41–47 % Si), FeSi50 (47–52 % Si) with the extraction degree of 70–87.6 % silicon into the alloy. Moreover, the ferrosilicon grade decreases with an increase in steel shavings in the charge from 21.9-31.4 % to 33–35 %. In comparison with ferrosilicon smelting from a standard charge containing quartzite with the crystalline form of SiO2, steel shavings and coke, ferrosilicon production from the mixture of amorphous rocks allows to increase the process rate by 17.5–21.6 %. It is possible to increase the silicon extraction degree into the alloy from 80-85 %–94.5 % if its final stage is carried out in the resistance mode. Widespread occurrence in nature, favorable conditions of occurrence, low cost, high reactive capacity are favorable factors for using amorphous rocks in the production of ferroalloys.