Ferro Alloy

Ferroalloy refers generally to ALLOYS of iron which contain a high proportion of one or more other elements than carbon. These include elements such as chromium, manganese or aluminum. The steel industry is the largest consumer of ferroalloys, as they impart various properties to steel alloys and stainless steel. In addition, ferroalloys play an important role in the production of the metal. For example, ferroalloys prevent the negative effects of sulfur in the production and improve the CORROSION RESISTANCE in steels.

In general, ferroalloys are produced in a blast furnace or an electric arc furnace, whereby the importance of the latter method declined steadily in the 20th century.

Other possibilities for the production of ferroalloys are by carbothermic reactions, the addition of elements into molten iron and by direct reduction.

Dif­fer­ent types of fer­roal­loys
Since each ferroalloy serves a different purpose, many types exist. These are the most common.

Fer­rochrome
Ferrochrome, also known as ferrochromium, typically consists of 50 to 70 % of chromium by weight. Basically, it is an alloy of chromium and iron. Ferrochrome is mainly used in the production of steel, which makes up for about 80 % of the world's consumption.

In general, ferrochrome is produced in an electric arc furnace. The production process is essentially a carbothermic reaction which is carried out at extreme temperatures near 2800 °C. A large amount of electricity is needed to reach these high temperatures. As a result, production in countries with high electricity costs is very expensive. The leading producer of ferrochrome is China, South Africa and Kazakhstan.

Fer­ro­man­ganese
Ferromanganese is characterized by a very high content of the element manganese. It can be produced in a blast furnace. However, more common is the production in a submerged arc furnace, which is a type of electric arc furnace. This is achieved through carbothermic reduction. For this process, a mixture of manganese oxide, iron oxide and carbon is heated.

High-carbon ferromanganese is the most consumed ferroalloy worldwide in terms of quantity and is widely used in steelmaking. China is the main manufacturer of this ferroalloy.

Fer­ro­molyb­de­num
Ferromolybdenum combines molybdenum and iron. This ferroalloy has a molybdenum content of 60 – 75 %. In the production process, molybdenum oxide is mixed with iron oxide and aluminium. An aluminothermy reaction follows. To purify the end product, an electro-beam melting is applied. The addition of ferromolybdenum leads to an improved corrosion and wear resistance and weldability.

Ferromolybdenum is mainly used in the production of ferrous alloys. Further applications are machine tools and equipment, military hardware, cars, trucks and ships. Moreover, it can also be applied in high speed tools steels and superalloy applications. The leading producers of ferromolybdenum are China, Chile and the US.

Fer­ronick­el
Ferronickel is characterized by a nickel content of 35 %. The ferroalloy is obtained by a carbothermic reaction and is often applied in the production of austenitic stainless steels and nickel alloy steels. In 2008, the steel making industry made up to 98 % of the ferronickel consumption in the US. Further applications are electronics and the manufacture of batteries. The main ferronickel producers are Japan, New Caledonia and Colombia.

Fer­rosil­i­con
Ferrosilicon is a ferroalloy which contains about 15 – 90 % of silicon by weight. Particularly high is the proportion of iron silicides. The manufacturing of the ferroalloy is carried out by reduction. In the process, silica, sand with coke or iron are used.

The main applications of ferrosilicon are in steel production. The ferroalloy helps to deoxidize steel and ferrous metals. Further, it improves hardness, strength and corrosion resistance. China is the main producer of ferrosilicon.

Fer­roti­ta­ni­um
Ferrotitanium is a ferroalloy which consists of 45 – 75 % of titanium. Further, iron and sometimes small amounts of carbon is added. For production, an induction furnace is used. In this, titanium, steel and iron are melted. Ferrotitanium is characterized by superior corrosion resistance, high strength and low density.

Mostly, ferrotitanium is applied in steel production. Further, the ferroalloy is used for deoxidizing and desulphurization. Main producers of ferrotitanium are Brazil, China and India.

Fer­ro­tung­sten
Ferrotungsten is a ferroalloy which is a combination of iron and tungsten. It is categorized into grade A (75 – 82 % W) and B (70 – 75 % W). In the production process, tungsten is converted into tungsten oxide. In the next step, it is heated with hydrogen or carbon. The resulting powder is mixed with iron. The raw material required is found in wolframite, scheelite and ferberite. The use of ferrotungsten increases the melting point of an alloy. As a result, the material is often used when the workpiece has to withstand high temperatures, for example in the aerospace industry.

Silicon-carbon alloy is a new type of alloy which can replace most of ferrosilicon, silicon carbide and recarburizer,thereby reducing the use of deoxidizer.It is utilized for smelting deoxidation alloying process in converter and it has stable effect,with better steel chemical composition,mechanical properties and internal quality control than traditional process.

Performance and features:
1.Improve the quality of molten steel,steel quality and performance.
2.Reduce the use of alloy therefore to reduce the cost of steel-making,Increase economic benefits.
3.Save energy, reduce environmental pollution.

Ferro silicon is an alloy composed of iron (Fe) and silicon (Si), where silicon typically constitutes about 15% to 90% of the alloy's composition. The exact composition can vary based on the specific requirements of different applications. The alloy is produced by melting a mixture of iron and high-purity quartz (silicon dioxide) in an electric arc furnace.

Key characteristics and uses of ferro silicon include:
Deoxidizing Agent: Ferro silicon is commonly used as a deoxidizing agent in the production of steel. It helps remove oxygen from the molten metal, preventing the formation of oxides that could negatively impact the quality of the steel.
Inoculant in Cast Iron Production: It is used as an inoculant in the production of cast iron to promote the formation of graphite, improving the cast iron's mechanical properties.
Alloying Agent: Ferro silicon is an alloying agent used to introduce silicon into various metals and alloys. It is particularly useful in the production of stainless steel, where silicon enhances corrosion resistance and heat resistance.
Improves Electrical Properties: In some applications, ferro silicon is used to improve the electrical conductivity of certain materials, such as in the manufacturing of electrical transformers.
Foundry Industry: It is employed in the foundry industry for the production of iron and steel castings.
Magnesium Reduction: Ferro silicon can be used in the magnesium reduction process to produce magnesium from dolomite.
Specification:
FeSi 75
Si:75%min

As a source of silicon to reduce metals from their oxides and to deoxidize steel and other ferrous alloys
Manufacture of other ferroalloys.

Manufacture of silicon, corrosion-resistant and high-temperature resistant ferrous silicon alloys, and silicon steel for electromotors and transformer cores.

Manufacture of cast iron, ferrosilicon is used for inoculation of the iron to accelerate graphitization.

Manufacture of prealloys like magnesium ferrosilicon, used for modification of melted malleable iron.

As an additive to cast irons for controlling the initial content of silicon.

In steel melting, casting, mineral processing and melting rod industry.

Used in the Pidgeon process to make magnesium from dolomite.

For heavy media separation and atomization.

Used in casting, melting and related metallurgy industry.

For production of semiconductor pure silicon in electric industry and silicon copper in chemistry industry.