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Plasma-arc technology provides an alternative method for the treatment of ferro-alloys, in which disadvantages can be obviated to some extent. The three basic processes that are applicable to the production and treatment of manganese ferro-alloys are: the smelting of the ore, the remelting of ferro-alloy fines or other physically unacceptable forms of the alloys, and the refining of the alloys to yield a product with a lower carbon or silicon content than that of the alloy produced initially. In the present study, plasma technology was applied to the production of manganese ferro-alloys, and its suitability was evaluated in the context of these three processes. Two furnaces were used in the tests: a 1400 kVA furnace manufactured by Tetronics Research and Development Limited (TRD) and a 100 kVA furnace at Mintek. Both furnaces employ direct current (dc), and operate with a single electrode as the cathode and the molten bath as the anode. The molten pool of process material forms an integral part of the electrical circuit, and the furnaces used in the experiments can therefore be classified as dc transferred-arc plasma furnaces. In the 1400 kVA furnace, a water-cooled tungsten cathode (plasma gun) was used; in the 100 kVA furnace, graphite or water-cooled tungsten was used as the cathode material. High-carbon ferromanganese fines were successfully remelted in the Mintek 100 kVA and the TRD 1.4 MVA furnaces. The TRD furnace was operated at a power level of 450 kW, and about 4.5 t of metal was tapped continuously over a period of 8 hours. The specific energy consumption was 795 kW.h per ton of metal produced, and the losses of manganese in the baghouse represented less than 1 per cent of the manganese in the feed. Silicomanganese was produced in the Mintek 100 kVA furnace by the simultaneous remelting of high-carbon ferromanganese and silicon fines. A sufficiently low level of carbon could be reached to meet the chemical requirements of a regular-grade silicomanganese, and the recoveries of manganese and silicon were 97 and 82 per cent respectively. In some instances, the carbon content of the product was even lower than its initial level in the silicon fines, indicating that the conditions for the removal of the carbon in the plasma system are very favourable. Experiments in the Mintek 100 kVA furnace demonstrated that, when high-carbon ferromanganese is refined by manganese ore at temperatures around 1600 degrees C, ferromanganese containing about 2 per cent carbon and 0.1 per cent silicon can be produced. Satisfactory results were obtained on synthetic ores with basicities of 1.4 and 2.4 at metal-to-ore ratios of 2:1. The overall losses of manganese were between 10 and 15 per cent. High-carbon ferromanganese was produced from manganese-ore fines in the Mintek 100 kVA and the TRD 1.4 MVA furnaces. The manganese oxide contents of the resulting slags were significantly lower than those reported for submerged-arc furnaces. The losses of manganese to the dust stream, however, were substantial and, at the least, about 10 per cent of the manganese in the feed was lost by evaporation and entrainment. The relatively small scale of operation and the use of finely sized feed materials probably enhanced the losses of manganese, which were substantially higher than in conventional submerged-arc furnaces. It would appear that, because of the open-bath configuration and the absence of a burden of charge material, the areas over which the feed materials and power are conveyed to the reaction zone should be optimized and controlled more carefully if the recoveries obtained by industry are to be attained. Further work is required so that losses to the dust can be reduced and the benefits that would result from the utilization of finely sized manganese ores and reducing agents can be realized. This is especially important to the possible future production of upgraded ore fines with high manganese-to-iron ratios from relatively low-grade ore deposits, and because fine reducing agents will be available from coal deposits where the beneficiation process necessitates reduction of the coal ore to fine particles.
The advantages of plasma systems over three-phase submerged-arc furnaces in their application to the production of ferro-alloys are examined briefly. The interaction between an arc and the metallurgical conditions in a plasma furnace is different from that in a submerged- arc furnace, particularly in the utilization of the energy of an arc. Experiments on the dissipation of energy in a transferred plasma arc are described, and the results, which give rise to the following conclusions, are given. There is a large dissipation of energy at the anode (up to 80 per cent), largely because the energy developed in the arc column is directed downwards onto the anode. The major factors affecting the relative proportion of energy dissipated at the anode are: the type and geometry of the cathode, since a strong cathode jet increases the proportion of energy directed at the anode; the arc current, since an increased arc current increases the proportion of energy at the anode; the arc length, since an increased arc length decreases the proportion of energy at the anode, although a large proportion of the energy is still directed through the anode region; the arc-supporting gas, since the use of nitrogen, a diatomic gas, results in a higher transfer of energy to the anode than for argon, a monatomic gas. The dissipation of energy from the arc column, (radiation energy) is relatively small. As long as the arc column is well collimated and directed downwards onto the anode (or the metal bath of the furnace), the exposed arc column does not cause extensive wear of the refractories. The major problems relating to the refractories in a transferred-arc furnace are slag attack on the walls of the furnace, refractory wear caused by convection energy generated in the arc column, and radiation to the roof of the furnace from the hot anode region and the molten bath. It is important for the reduction reactions to be carried out in the hot anode region, or as close as possible to it, so that the energy at the anode will be quenched. This is particularly important in ferro-alloy production in the open-bath mode.
The Complete Book on Ferroalloys (Ferro Manganese, Ferro Molybdenum, Ferro Niobium, Ferro Boron, Ferro Titanium, Ferro Tungsten, Ferro Silicon, Ferro Nickel, Ferro Chrome) An alloy is a mixture or solid solution composed of metals. Similarly, Ferroalloys are the mixture of Iron with high proportion of other elements like manganese, aluminium or silicon. Alloying improves the physical properties like density, reactivity, Young’s modulus, electrical and thermal conductivity etc. Ferroalloys thus show different properties as mixture of different metals in different proportion exhibit a wide range of properties. Also, Alloying is done to alter the mechanical properties of the base metal, to induce hardness, toughness, ductility etc. The main demand of ferroalloys, nowadays is continuously increasing as the major use of such products are in the field of civil construction; decorative items; automobile; steel industry; electronic appliances. The book provides a wide idea to readers about the usage of appropriate raw material and the treatment involved in the processing of raw material to final produce, safety, uses and properties of raw material involved in the processes. This book concisely presents the core principles and varied details involved in processing of ferroalloys. The work includes detailed coverage of the major products like ferroaluminium, ferrosilicon, ferronickel, ferromolybdenum, ferrotungsten, ferrovanadium, ferromanganese and lesser known minor ferroalloys. Progress in thermodynamics and physico-chemical factors in ferroalloy production has developed rapidly during the past twenty-five years or so. The book presents the principles and current knowledge of processes in the production of various ferroalloys. The production of a particular ferroalloy involves a number of processes to be followed in order to give the alloy desired physical and mechanical properties. The slight difference in the temperature or heating or composition can lead to entirely different alloy with different properties. This book is not only confined to the different processes followed in the production of ferroalloys but also describes the processes used and other information related to product, which are necessary for the manufacturer’s knowledge. Also, the book gives the reader appropriate knowledge regarding the selection the best of available raw materials. TAGS Book on Ferroalloys, Business consultancy, Business consultant, Business Plan for Ferroalloys manufacturing plant, Ferro Alloy Industries Consultant, Ferro alloy industry in India, Ferro Alloy Projects, Ferro alloys industry, Ferro alloys industry about Ferro alloys, Ferro alloys manufacturers, Ferro alloys manufacturing Process, Ferro alloys plant, Ferro Alloys Process, Ferro alloys Production Industry in India, Ferro alloys Production processes, Ferro alloys production technology, Ferro alloys uses, Ferro Alloys, Ferro Manganese, Ferro Molybdenum, Ferro Niobium, Ferro Boron, Ferro Titanium, Ferro Tungsten, Ferro Silicon, Ferro Nickel, Ferro Chrome, Ferroalloy production, Ferroalloys & Alloying Additives, Ferroalloys Based Projects, Ferroalloys Business Manufacturing, Ferroalloys manufacturing, Ferroalloys manufacturing Business, Ferroalloys production line, Ferroalloys Theory and Technology, Ferrous metals and ferroalloys processing, Great Opportunity for Startup, High Carbon Ferro Alloys, How to Start a Ferroalloys Production Business, How to start a successful Ferroalloys manufacturing business, How to Start Ferro alloys Production Industry in India, Ideas in Ferroalloys processing industry, Indian Ferro alloy industry, Indian Ferro alloy industry - present status and future outlook, Indian Ferro alloys industry: a review, Indian Ferro alloys producers, India's Ferro Alloys Industries, Industrial Project Report, Integrated Ferro Alloys, Manufacture in India of Ferroalloys used in alloy steel, Most Profitable Ferro alloys manufacturing Business Ideas, Niir, NPCS, On the role of ferroalloys in steelmaking, Pollution Control in Ferroalloy Production, Process technology books, Production of Ferro Boron, Production of Ferro Molybdenum, Production of Ferro Nickel, Production of Ferro Niobium, Production of Ferro Titanium, Production of Ferro Tungsten, Production of Ferroalloys, Production of Manganese Ferroalloys, Production Process of Ferro Chrome, Production Process of Ferro Silicon, Production Techniques of Ferroalloys, Profitable Ferroalloys manufacturing Industry, Project consultancy, Project consultant, Proposed Ferro Alloys & Integrated Steel Plant, Setting up and opening your Ferroalloys Business, Starting a Ferroalloys manufacturing Process Business, Technology of Ferro Alloys Making, Technology used in Ferro Alloys plant, What are Ferroalloys?, What are the uses of Ferro alloys and how they are used?
Thermal plasma has been applied to the melting of high-value metal fines for some time; only recently was attention given to the use of this technology for the melting of materials of lower value. Typically, these materials arise on ferro-alloy plants as the undersize when brittle alloys are crushed and then screened to the customer's size requirement. Because of their physical properties, these fines are not usually suitable for remelting in conventional furnaces. Promising results were obtained by the Council for Mineral Technology in experimental campaigns on the remelting of ferrochromium, ferromanganese, and silicon fines in transferred-arc plasma furnaces. The results of some of the tests are discussed. Directly reduced iron can be regarded as a form of metal fines and, as such, should be amenable to processing in a transferred-arc plasma furnace. A strong case is made for the use of plasma technology for that purpose, although the scale of operation will be limited at present owing to the current state-of-development of the art. Although transferred- arc plasma systems offer many advantages, there are problems associated with the technique, and possible solutions to some of these problems are presented.
Plasma-furnace technology was first applied in Africa in the mid- to late 1970s, when it was realized that advantages could be obtained in the processing of fines for the production of ferro-alloys. A number of processes have been implemented on an industrial scale, including the four 105 MVA ilmenite-smelting furnaces (AC transferred-arc) at Richards Bay Minerals, the 40 MVA ferrochromium furnace (DC transferred-arc) at Palmiet Ferrochrome, Krugersdorp, and the 11 MVA ferromanganese 'boot' furnace (DC transferred-arc) at Metalloys, Meyerton. Well-developed plasma-furnace research facilities are in place in South Africa, and include the 3,2 MVA DC transferred-arc plasma furnace at Mintek, Randburg. This paper highlights some of the applications of plasma technology to a variety of ores, minerals, concentrates, metals, and chemicals. The development of successfully-implemented plasma systems is described, as well as the problems that have been experienced with some of the less-successful activities.