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2015-12-25 Ukraine: The Technology of Producing Low Carbon Ferrochrome by the Method of Silicothermic Duplex Process


The Technology of Producing Low Carbon Ferrochrome by the Method of Silicothermic Duplex Process

Description of the project offered: 
Topic: SC5-13-2016-2017 New solutions for sustainable production of raw materials

The volume of world ferrochrome consumption is estimated at 7-8 million tons.
World production of ferrochrome, especially related with the production of stainless steel grades ordinary and special purpose, uses about 90% of the world production of ferrochrome. The demand for stainless steel increases by 7% per year.
The world price of low carbon ferrochrome is growing every year. 

In the framework of this project it is proposed to introduce technology for producing low carbon ferrochrome by the method of silicothermic duplex process based on the mixing ore-lime melt with ferrochrome silicon in the reactor with the intensification of the chromium recovery processes by blowing with an inert gas. 
There are several ways of obtaining low-carbon ferrochrome, the main of which are the following:
1. Silicothermic method of smelting of ferroalloy in the electric furnace.
2. Liquid mixing ore-lime melt with ferrochrome silicon in the ladle.
3. Refining of liquid or solid ferrochromium in a vacuum.
The disadvantages of the first method of ferrochrome production are:
- long time exposure of the metal and slag in the furnace, which leads to an increase of carbon content in ferrochrome;
- waste slag contains a high percentage of chromium oxide (deadweight loss);
- extraction of chromium from ore is 72-78%.
The disadvantages of the second method of production are:
- excess of maximum allowable concentrations of industrial emissions in the shop on the workplace and the impossibility of their complete localization in connection with crane operations overflow of the melt;
- loss of melt temperature in the overflow (temperature of ferrochrome is close to crystallization);
- low resistance of the ladle lining;
- difficulties in ensuring the regulated technological process of the cyclical operation of the equipment.
The disadvantage of the third method is low productivity.
The proposed technology allows:
- to produce low-carbon ferrochrome, which meets all the requirements of international standard DIN 17565 with carbon content in the alloy from 0.01% of its mass fraction;
- to increase the recovery of chromium from the ore into a marketable product up to 97%;
- to lower the growing deficit of low carbon ferrochrome for manufacturers of stainless steels;
- to strength the market position of Europe in the production of low carbon ferrochrome.
The basis of the developed technical solutions is part of energy - saving technologies and equipment, providing high technical and economic indicators of production and minimal harmful impact on the environment.
According to preliminary estimates the payback period of capital cost for implementation of proposed technology is 2 – 2.5 years.
Project proposer:   Vadym Mantula (Ukraine)
Partner role:  Project participant 
Partner organisation:  Industry
Call for proposal title:  Greening the Economy 
Call for proposal identifier:  H2020-SC5-2016-2017

Description of the collaboration sought: 
We invite all partners interested in implementation of the proposed idea 
Expertise sought: Intellectual property rights, Business aspects, Scientific research, Coordination. Cooperation, Innovation. Technology transfer, Evaluation, Policies, Security, Employment issues, Regional development, Economic aspects, Social aspects, Climate change and Carbon cycle research, Sustainable development, Waste management, Environmental protection, Project management methodologies, Standards, Measurement methods, Other energy topics, Energy saving, Fossil fuels, Other technology, Materials technology, Construction technology, Industrial manufacture, 
Roles sought: Project coordinator, Project participant, 
Organisation types sought: 
Countries sought: Belgium, Bulgaria, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, United Kingdom, Albania, Bosnia and Herzegovina, Croatia, Iceland, Israel, Liechtenstein, Macedonia, the former Yugoslav Republic of, Montenegro, Norway, Serbia, Switzerland, Turkey, China, India, Japan, Ukraine, United States, 

Call for proposal specific information
The referenced call for proposals has no specific fields defined.