Electric Arc Metallothermic Smelting of FeCr Using FeAlSiCa as a Reductant

This study investigates the use of the complex reductant FeAlSiCa as an alternative to the conventional FeSiCr in the EAF smelting of FeCr. The smelting process using FeAlSiCa is characterized by a stable furnace operation, active discharge of metal and slag, and effective phase separation. It was found that a 20% excess of FeAlSiCa over the stoichiometric requirement leads to a sharp increase in Si content in the FeCr alloy, with approximately 85% Cr recovery into the metal. A stoichiometric amount of FeAlSiCa results in a metal with 1.5-1.6% Si content and about 80% Cr recovery. A comparable Cr recovery using FeSiCr was achieved only when applying a 20% excess of that reductant. The use of FeAlSiCa also holds promise for technological sustainability due to its low production cost and the utilization of waste materials during its synthesis. The resulting slags are solid and rock-like and show no signs of disintegration after storage for more than 45 days.