001 - The development of a Technology Roadmap for Ferrochrome Producers

Question 1

When did the Production of ferroalloys start

Answer 1

In the 1860s

Question 2

Which ferrocalloys were processed intially? Reason for this?

Answer 2

So initially, ferromanganese, ferrosilicon, ferrovanadium and ferrotitanium could be produced. Ferrochrome however could not be produced, owing to the high melting temperatures required for ferrochrome slag

Question 3

How did South Africa’s market share change over the years in terms of Ferrochrome Production

Answer 3

In 2001 RSA had 50% of the market. In 2011 the South African Market share dropped to 36% and China was on 30%

Question 4

Which smelters make use of the Premus technology

Answer 4

Basically only Lion

Question 5

Which companies use DC arc furnaces?

Answer 5

Samancor and Mogale Alloys

Question 6

Which technologies are more energy efficient?

Answer 6

Premus and DC arc furnaces are more energy efficient that conventional furnaces

Question 7

According to this article methane/natural gas can be used as a reductant?

Answer 7

Yes, but referencing a different article. So apparently methane can be used for reducing ferro-alloy ores in solid state at lower temps than the known carbothermic reduction reactions. Will continue researching this.

Question 8

Canada has ferrochrome deposits? True or False

Answer 8

They do have. Energy requirements are a concern to them as well, so Natural Resource Canada was mandated to innovate new technologies for the direct reduction of ferrochrome ore using different fluxes or catalysts

Question 9

One of the key findings of Natural Resource Canada when they were tasked to investigate alternative methods for ferrochrome reduction

Answer 9

They found that when you add NaOH (caustic soda) directly to ferrochrome ore, metallisation will take place at lower temperatures.

Question 10

What is Colemanite?

Answer 10

It is considered to be a type of flux, which could lead to a decrease in process temps from 1750C to 1650C, whilst still maintaining good slag flow. So silica reduces the liquidus temperature, but it is CaO that improves flow (but makes the liquidus temp higher again). Lastly, colemanite originates from Turkey, so will be an expensive fluxing agent.

Question 11

According to this article, which fruits are hanging lowest to the ground, which should receive attention in order to decrease energy costs

Answer 11

The possibility of heat recovery from the flue gas (and other sources?)

Question 12

Key ideas that stood out from this article and other ideas: (daai sustainability report)

Answer 12

1. Co generation
2. Ways to preheat the ore? Fluid bed technology
3. further slag treatment
4. real time information processing to control the furnaces
5. Machine learning
6. Cloud connectivity