METHOD FOR PRODUCTION OF IRON-SILICON-ALUMINUM ALLOYS AND THEIR USE

Abstract

Method of producing FeSiAI alloys wherein a carbonaceous rock with an ash content >50% to <65%, is being mixed with quartzite, iron-bearing material, and wood chips, if required, high volatile coal, in a preset ratio of the charge components and the homogenized charge material is being loaded into a melting furnace for melting of FeSiAI alloy, the charged carbonaceous rock can contain i.a. the following chemical composition in the mineral part (ash): Fe.sub.2O.sub.3 1.5-4.5% SiO.sub.2 55-65% Al.sub.2O.sub.3 25-35%, especially 32-34% CaO 0.3-3% MgO 0.3-2% TiO.sub.2 up to 1.5 S>0-0.4%, especially 0.01-0.06% P 0.01-0.05%

Claims

1. A method of producing FeSiAl alloys wherein a carbonaceous rock with an ash content >50% to <65%, is being mixed with quartzite, iron-bearing material, and wood chips, if required, high volatile coal, in a preset ratio of the charge components and the homogenized charge material is being loaded into a melting furnace for melting of FeSiAl alloy, the charged carbonaceous rock can contain i.a. the following chemical composition in the mineral part (ash): TABLE-US-00046 Fe.sub.2O.sub.3 1.5-4.5% Si0.sub.2 55-65% Al.sub.2O.sub.3 25-35%, especially 32-34% CaO 0.3-3% MgO 0.3-2% TiO.sub.2 up to 1.5% S >0-0.4%, especially 0.01-0.06% P 0.01-0.05%

2. The method under claim 1, wherein the charge materials are mixed and homogenized outside the melting furnace, and then the homogenized charge is loaded dosed into the melting furnace equipped with electrodes cone up, and then the FeSiAl alloy is being smelted.

3. The method under claim 1, wherein the carbonaceous rock has a size >20 to 80 mm, the quartzite has a size 25 to 60 mm and the iron-bearing material has a size 5 to 100 mm, in particular 5 to 50 mm.

4. The method under claim 1, wherein the wood chips or the high volatile coal has a size 50-100 mm.

5. The method under claim 1, wherein while using the wood chips the raw material has >50% of volatile matter.

6. The method according to claim 1, wherein while using high volatile coal the raw material has >40% volatile matter.

7. The method under claim 1, wherein the charge materials carbonaceous rock, quartzite and iron-containing material, if required wood chips or high volatile coal are stored in separate bins (hoppers) with the required fraction size and, depending on the capacity of the melting furnace, are mixed in a preset ratio and are loaded dosed into the melting furnace equipped with Sderberg electrodes.

8. The method under claim 1, wherein carbonaceous rock with high electrical resistance is used as a raw material, in particular with an electrical resistance between 10.sup.6 and 10.sup.1.

9. The method under claim 1, wherein, if required, the following oxide materials containing Mn, Ca, Ba, Cr, V, Ti are being individually added to the charge materials.

10. The method under claim 9, wherein the quantity of the oxide material added, if required, to the composition of the charge, secures the following composition of the charge: TABLE-US-00047 Ca 0.05-7.0% Ba 1.5-15% V 0.5-10% Ti 0.05-10% Mn 5-20% Cr 5-20%

11. The method under claim 1, wherein FeSiAl alloys with the following chemical composition is being melted in the melting furnace (mass-%): TABLE-US-00048 Si 40-85% Al >1-<40% C >0.001-<1.0% Ti max 2% Ca <1.0% P <0.05% S <0.1% Mn max 0.7% Fe balance

12. The method under claim 10, wherein manganese in form of oxide material is added, if required, to the charge material whereby a FeSiAl alloy with the following chemical composition is melted in the melting furnace: TABLE-US-00049 Si 40-65% Al >1-<40% C >0.001-<0.40% Ti max. 1.5% Ca <4.0% P <0.05% S <0.05% Mn 5-20% Fe balance and in the same manner, if required, are added Ca, Ba, V, Ti and Cr in form of oxide materials to secure the content of these elements, each of them individually, as per claim 10.

13. The FeSiAl alloy produced under the method of claim 1 is used for reducing and doping of steel.

14. The FeSiAl alloy produced under the method of claim 1 is used for production of magnesium.

15. The FeSiAl alloy produced under the method of claim 1 is used for production of refined grades of ferroalloys.

16. The method under claim 2, wherein the carbonaceous rock has a size >20 to 80 mm, the quartzite has a size 25 to 60 mm and the iron-bearing material has a size 5 to 100 mm, in particular 5 to 50 mm.

17. The method under claim 2, wherein the wood chips or the high volatile coal has a size 50-100 mm.

18. The method under claim 3, wherein the wood chips or the high volatile coal has a size 50-100 mm.

19. The method under claim 2, wherein while using the wood chips the raw material has >50% of volatile matter.

20. The method under claim 3, wherein while using the wood chips the raw material has >50% of volatile matter.

Description

[0064] Examples of embodiments of the invention are presented and described as follows:

[0065] FIGS. 1 to 3 Diagram of handling and processing of raw materials, carbonaceous rock, quartzite and iron turnings;

[0066] FIGS. 4 and 5 Diagrams of the melting furnace with several electrodes in different views.

[0067] FIGS. 1-3 show the diagrams of handling and processing of raw materials, carbonaceous rock, quartzite and iron turnings;

[0068] FIGS. 1 and 2 are constructed similarly, thus FIG. 1 represents crushing and screening of carbonaceous rock and FIG. 2 the same of quartzite.

[0069] The supplied carbonaceous rock 1 is being fed to the bin (hopper) 2 connected to a vibration feeder 3 or a similar device. Through the only indicated conveyor 4 the carbonaceous rock 1 gets into the crusher 5, for example a jaw crusher. In this way the crushed carbonaceous rock 1 is being screened with a screen 6 to grain sizes 0 to 20 mm and >20 to 80 mm. Grain size >20 to 80 mm is further being used in the furnace charge.

[0070] FIG. 2 represents handling of quartzite 7 which is also being fed into bin (hopper) 8. From the vibrating feeder 9 and conveyor belt 10 quartzite is transported to the crusher unit 11, another jaw crusher, if required, and then is being screened through screen 12 to grain sizes 0 to 25 mm, as well as >25 to 60 mm. Size >25 to 60 mm is being further used for production. If quartzite 7 is not crushed/screened on-site it can be delivered already crushed.

[0071] In further process stages the respective mixture (carbonaceous rock >20 to 80 mm, quartzite >25 to 60 mm) is being fed via conveyors to hoppers 13, 14 (FIG. 3).

[0072] Another hopper 15 contains also required primary materialiron-turnings 15a with size between 5 and 100 mm, preferably 5 to 50 mm. Through a dosing strain-gauge weigher 16, 17, 18 the preset portions of carbonaceous rock 1 (hopper 13), quartzite 7 (hopper 14), as well as iron turnings 15a (hopper 15) are being transported to a belt conveyor 19, whereby the primary materials 1, 7, 15a are being homogenized.

[0073] If required another hopper B can be fed with wood chips H, size 50-100 mm, which is admixed to the charge consisting of carbonaceous rock 1, quartzite 7 and iron turnings 15a. As described earlier it is possible to use high-volatile coal instead of wood chips H.

[0074] Via next transport equipment/device 20, shown here as a belt conveyor, the prepared homogenized furnace charge material consisting of carbonaceous rock 1, quartzite 7 and iron turnings 15a (if required wood chips H) is being discharged into the furnace (not shown here). If necessary further homogenization steps like screw mixing or similar can be conducted on the way to the furnace (which is not shown here).

[0075] FIGS. 4 and 5 represent a simplified execution of the melting furnace 23 containing several Sderberg electrodes 21. The arrows designate directions of discharging of the homogenized furnace charge consisting of carbonaceous rock 1, quartzite 7 and iron turnings 15a and if required wood chips H loaded in the only in the designated conical form 22 around the electrodes 21. If the conical form is impossible to reach, special mechanical auxiliary devices such as scrapers, etc. come to action in order to achieve this conical form.

[0076] Further the object of the invention is described more detailed in examples:

[0077] For example: the following homogenized furnace charge materials are used to produce FeSiAl 65/15: [0078] A. Carbonaceous rock, 3 tons, ash content 50-55%, grain size >20-80 mm Ash chemical analysis

TABLE-US-00010 SiO.sub.2 55-60% Fe.sub.2O.sub.3 1.5-4.5% Al.sub.2O.sub.3 32-34% CaO 0.3-3.0% TiO.sub.2 0.8-1.2% S 0.02-0.04% P 0.01-0.05% [0079] B. Quartzite, 0.4-1.3 tons, grain size 25-60 mm

TABLE-US-00011 SiO.sub.2 >97% Al.sub.2O.sub.3 1.0% Fe.sub.2O.sub.3 + CaO + MgO + P.sub.2O.sub.3 2% [0080] C. Iron Turnings >0-0.5%

[0081] Raw Material

[0082] Carbonaceous raw material (high-ash coal with ash content 45-50%, carbonaceous rock with ash content 55-65%) is characterized through different content of ash, volatiles and humidity. For example one batch of carbonaceous raw material may contain lumps with different ash content. Therefore it is very important to blend the composition of the supplied batch of the carbonaceous raw material. This can be achieved through its thorough mixing during crushing and screening and also during its storage.

[0083] Quartzite is being delivered already screened. The effective screen size is 25-60 mm.

[0084] Iron turnings are being delivered crushed with 5-50 mm screen size. 50-100 mm oversize should not exceed 10%. The iron turnings can be oxidized. Oxide film thickness should not exceed 0.7 mm.

[0085] 1.1. Crushing and Screening of Raw Materials

[0086] The unit for furnace charge handling consists of a standard set of a jaw crusher and a screenthe crushing and screening unit (CSU). The set contains a bin (hopper) with a vibration feeder in which a pay-loader loads the carbonaceous stock. And the raw materials are transported to the bin (hopper) from different parts of the heap. From the bin (hopper) the raw materials are moved proportionally and uniformly to the crusher with 100 mm distance between the crusher jaws. After crushing the carbonaceous stock is transported to the screen having a mesh of 20 mm where the raw materials are screened into two sizes of 0 to 20 mm and >20 to 80 mm. Size >20 to 80 mm is the effective size needed for the production and is being stored.

[0087] 1.2. Storage of the Carbonaceous Stock

[0088] After crushing the effective size of the carbonaceous raw material is stored in even layers on the whole defined surface. This is achieved by using a traversing conveyor with a splitter or directly by a pay-loader. Thus is obtained a pile of 3-4 layers of the carbonaceous stock. The feeding of the carbonaceous stock to the weighing bin (hopper) is done from the end of the pile while the layers are being mixed.

[0089] In this way mixing and blending of the raw material batch is made during crushing, piling and charging of the carbonaceous stock into the weighing bin (hopper).

[0090] 1.3. Weighing of Raw Materials

[0091] Weighing is carried out with the use of common batching units consisting of a 20-60 m.sup.3 dispensing bin (hopper), a vibration feeder, tensometric balance of strip or bin type, reversible-shuttle belt. There should be at least three batching units for the carbonaceous stock, 1-2 units for the quartzite and 1 unit for the iron turnings. The three batching units for the carbonaceous stock are designated for batching different batches with various ash contents. Hence it is possible to mix in different proportions the carbonaceous material of 45% and 65% ash content or coal with 30% ash content and carbonaceous rock with 65% ash content thus obtaining the required ash content needed to smelt one or another alloy grade.

[0092] The basic batching unit is one of the weighing bins (hoppers) for carbonaceous raw material depending on the speed with which other raw materials are transported for weighing. After weighing all raw materials are fed to one reversible-shuttle belt. The raw material is placed layer-wise on it. Thereby is reached a uniform distribution of the carbonaceous raw material, the quartzite and the iron turnings. Further the charge mix is discharged from the reversible-shuttle belt to the inclined belt conveyer which feeds the charge mix to the melting shop on a mark with the furnace bins (hoppers).

[0093] 1.4. Furnace Bins (Hoppers) and Furnace Bath Charging

[0094] The charge gets from the inclined belt conveyer through a hopper mechanism to a running inclined belt conveyor on the furnace bins (hoppers) mark over the furnace bath. The furnace bins (hoppers) are sequentially fed by furnace charge. The charge from the furnace bins (hoppers) is discharged into the furnace bath through charging tubes, if necessary, and depends on the speed of its smelting in the furnace bath. There are ten charging tubes, i.e. three near each electrode and one charging tube in the center between the electrodes. The charge is steadily fed to the electrodes. If required it is scraped to the electrodes with special steel scrapers (for small electric furnaces of up to 5 MVA) or with special devices for charge distribution (for electric furnaces of 10-33 MVA) to the electrodes creating 300-600 mm high charge cones around the electrodes. It improves settling of fumes of gaseous silicon (SiO) and aluminum (Al.sub.2O) suboxides.

[0095] The ferrosilicon aluminum smelting process can be divided into three intervals depending on the temperature and preferential behavior of the different reactions.

[0096] The temperature interval/range of T=1,400-1,500 C. is characterized by active decrease in mullite concentration in the reaction mixture. Following reactions are taking place in this temperature interval/range depending on the way of heating the charge in this temperature interval/range:

SiO.sub.2,solid+C.sub.solid={SiO}+CO(1)

SiO.sub.2,solid+2C.sub.solid+Fe=SiFe+2CO(2)

[Si]+C.sub.solid=SiC(3)

SiO+C.sub.solid=Si.sub.liquid+CO(4)

{SiO}+2C.sub.solid=SiC.sub.solid+CO(5)

SiO.sub.2 solid.fwdarw.SiO+O.sub.2(7)

SiO.sub.2 solid+CO={SiO}+CO.sub.2(7)

Al.sub.2O+C.sub.solid=2Al.sub.liquid+CO(8)

[0097] Among them the greatest product yield is only produced by the reaction leading to formation of silicon carbide. The change of its quantity in the reaction mixture is characterized by prompt burst starting from temperature >1.550 C.

[0098] In a temperature interval/range 1,650-2,050 C. in the wake of temperature rising the following reactions start to run:

SiO.sub.2,solid+Si.sub.liquid=2SiO(9)

SiO.sub.gas+SiC.sub.solid=2Si.sub.liquid+CO(10)

SiO.sub.2+SiC=SiO+Si+CO(11)

[0099] With further rise of temperature (above 1,800 C.) following reactions are developing:

2Al.sub.2O.sub.3 solid+9C.sub.solid=Al.sub.4C.sub.3 solid+6CO(12)

2Al.sub.4C.sub.3 solid+3SiO.sub.2=8Al.sub.liquid+3Si.sub.liquid+6CO(13)

Al.sub.2O.sub.3+2SiC+Fe=2SiFe+ 4/3AlFe+2CO(14)

Al.sub.2O.sub.3 solid+2C=Al.sub.2O+2CO(15)

Al.sub.2O.sub.3 solid+3C=2Al.sub.l+3CO(16)

Al.sub.2O.sub.3+SiC=Al.sub.2O+SiO+CO(17)

[0100] A specific feature of this temperature interval/range is the formation of aluminum carbide which is easily neutralized in surplus of silica with formation of ferrosilicon aluminum.

[0101] At temperatures over 2,050 C. the content of silicon carbides in the charge drops substantially and concentration of silicon and aluminum in the metal rises. Whereby the silicon carbide is mainly consumed for interaction with alumina, Si- and Al-suboxides with formation of a silicon-aluminum alloy:

2Al.sub.2O.sub.3+SiC.sub.solid=4Al.sub.liquid+SiO.sub.gas+CO(18)

Al.sub.2O.sub.gas+SiC.sub.solid=2Al.sub.liquid+Si.sub.liquid+CO(19)

Al.sub.liquid.fwdarw.Al.sub.gas(20)

[0102] But simultaneously form >2,100 C. temperature level the evaporation of aluminum increases.

EXAMPLE 1

[0103] This example presents a ferrosilicon aluminum alloy in the charge of which was added manganese as oxide material, besides carbonaceous rock, quartzite and iron turnings (wooden chips if required).

[0104] FeSiAl Alloys with Manganese

[0105] A. Carbonaceous rock 2.99 tons, size >20-80 mm

TABLE-US-00012 Ash content (on dry mass) 53.4%; Volatile matter (on dry mass) 18.3% Humidity 4.0% Ash composition: SiO.sub.2 63.2% Fe.sub.2O.sub.3 2.5% Al.sub.2O.sub.3 31.7% CaO 1.1% TiO.sub.2 0.9% MgO 0.3% S 0.018% P 0.012%

[0106] B. Quartzite0.126 tons, size 25-60 mm

TABLE-US-00013 SiO.sub.2 97.5% Al.sub.2O.sub.3 1.0% Fe.sub.2O.sub.3 0.6% CaO 0.5% MgO 0.2% (oxides P, S, Na, K, Ti) <0.2% (balance)

[0107] C. Iron turnings0.09 tons, size 5-30 mm

TABLE-US-00014 Fe.sub.total 98.6% Si, Al, C balance

[0108] D. Manganese ore 0.457 ton, size 10-60 mm

TABLE-US-00015 Mn.sub.2O.sub.3 53.9% Fe.sub.2O.sub.3 7.9% SiO.sub.2 26.2% Al.sub.2O.sub.3 1.7% CaO 5.2% TiO.sub.2 0.1% MgO 1.0% S 0.02% P 0.02% Ignition losses 3.96%

[0109] At the end of the melting process is obtained a FeSiAl alloy with Manganese with the following average composition (mass-%):

TABLE-US-00016 Si 45.2 Al 18.8 Mn 14.6 C 0.25 Ti 0.6 Ca 1.2 P 0.01 S 0.001; Fe balance

EXAMPLE 2

[0110] This example presents a ferrosilicon aluminum alloy in the charge of which was added barium as oxide material besides carbonaceous rock, quartzite and iron turnings (wooden chips if required).

[0111] FeSiAl with Barium

[0112] A. Carbonaceous rock 3.03 tons, size >20-80 mm

TABLE-US-00017 Ash content (on dry mass) 55.2% Volatile matter (on dry mass) 18.7% Humidity 5.1% Ash composition: SiO.sub.2 60.9% Fe.sub.2O.sub.3 2.2% Al.sub.2O.sub.3 34.2% CaO 1.5% TiO.sub.2 1.0% MgO 0.12% S 0.014% P 0.016%

[0113] B. Quartzite0.397 tons, size 25-60 mm

TABLE-US-00018 SiO.sub.2 97.3% Al.sub.2O.sub.3 1.2% Fe.sub.2O.sub.3 0.7% CaO 0.4% (MgO + TiO.sub.2 + P.sub.2O.sub.5 + S + MnO + Cr.sub.2O.sub.3) <0.4%-balance

[0114] C. Iron turnings0.091 tons, size 5-30 mm

TABLE-US-00019 Fe.sub.total 98.6% Si, Al, C balance

[0115] D. Barium ore0.306 tons, size 10-50 mm

TABLE-US-00020 BaSO.sub.4 81.3% SiO.sub.2 15.2% Fe.sub.2O.sub.3 1.4% Al.sub.2O.sub.3 0.82% CaO 1.2% MgO 0.06% P.sub.2O.sub.5 0.02%

[0116] At the end of the melting process is obtained a FeSiAl alloy with Barium with the following average composition (mass-%):

TABLE-US-00021 Si 51.3 Al 20.7 Ba 10.7 C 0.15 Ti 0.6 Ca 0.8 P 0.011 S 0.002 Fe balance

EXAMPLE 3

[0117] This example presents a ferrosilicon aluminum alloy in the charge of which was added calcium as oxide material besides carbonaceous rock, quartzite and iron turnings (wooden chips if required).

[0118] FeSiAl Alloy with Calcium

[0119] A. Carbonaceous rock 3.17 tons, size >20-80 mm

TABLE-US-00022 Ash content (on dry mass) 55.2% Volatile matter (on dry mass) 18.7% Humidity 4.5% Ash composition: SiO.sub.2 60.9% Fe.sub.2O.sub.3 2.2% Al.sub.2O.sub.3 34.2% CaO 1.5% TiO.sub.2 1.0% MgO 0.17% S 0.014% P 0.016%

[0120] B. Quartzite0.42 tons, size 25-60 mm

TABLE-US-00023 SiO.sub.2 97.3% Al.sub.2O.sub.3 1.2% Fe.sub.2O.sub.3 0.7% CaO 0.4% (MgO + TiO.sub.2 + P.sub.2O.sub.5 + S) <0.4% - balance

[0121] C. Iron turnings0.11 tons, size 5-30 mm

TABLE-US-00024 Fe.sub.total 98.6% Si, Al, C - balance.

[0122] D. Lime0.143 tons, size 10-30 mm

TABLE-US-00025 SiO.sub.2 4.6% Fe.sub.2O.sub.3 2.5% Al.sub.2O.sub.3 1.3% CaO 86.4% MgO 4.4% P.sub.2O.sub.5 0.12% Ignition losses 0.68%

[0123] At the end of the melting process is obtained a FeSiAl alloy with Calcium with the following average composition (mass-%):

TABLE-US-00026 Si 53.2 Al 20.5 Ca 6.5 C 0.19 Ti 0.64 P 0.013 S 0.001 Fe balance

EXAMPLE 4

[0124] This example presents a ferrosilicon aluminum alloy in the charge of which was added chrome as oxide material besides carbonaceous rock, quartzite and iron turnings (wooden chips if required).

[0125] FeSiAl Alloy with Chrome

[0126] A. Carbonaceous rock 3.0 tons, size >20-80 mm

TABLE-US-00027 Ash content (on dry mass) 50.1% Volatile matter (on dry mass) 18.4% Humidity 4.1% Ash composition: SiO.sub.2 64.8% Fe.sub.2O.sub.3 2.6% Al.sub.2O.sub.3 30.4% CaO 0.96% TiO.sub.2 1.12% MgO 0.1% S 0.012% P 0.008%

[0127] B. Quartzite0.455 tons, size 25-60 mm

TABLE-US-00028 SiO.sub.2 97.2% Al.sub.2O.sub.3 1.0% Fe.sub.2O.sub.3 0.6% CaO 0.2% (MgO + TiO.sub.2 + P2O.sub.5 + S) <1.0% - balance

[0128] C. Iron turnings0.1 t, size 5-30 mm

TABLE-US-00029 Fe.sub.total 98.6% Si, Al, C balance.

[0129] D. Chrome ore 0.325 t, size 8-50 mm

TABLE-US-00030 Cr.sub.2O.sub.3 47.35% FeO 13.57% SiO.sub.2 9.5% Al.sub.2O.sub.3 7.5% CaO 0.4% MgO 18.0% S 0.01% P 0.008% Ignition losses 3.66%

[0130] At the end of the melting process is obtained a FeSiAl alloy with Chrome with the following average composition (mass-%):

TABLE-US-00031 Si 52.4 Al 18.1 Cr 16.0 C 0.24 Ti 0.50 Ca 0.63 P 0.011 S 0.001 Fe balance

EXAMPLE 5

[0131] The following example presents a ferrosilicon aluminum alloy in the charge of which was added vanadium as oxide material besides carbonaceous rock, quartzite and iron turnings (wooden chips if required).

[0132] FeSiAl Alloy with Vanadium

[0133] A. Carbonaceous rock 2.93 tons, size >20-80 mm

TABLE-US-00032 Ash content (on dry mass) 53.4% Volatile matter (on dry mass) 18.1% Humidity 4.7% Ash composition: SiO.sub.2 62.2 Fe.sub.2O.sub.3 2.6% Al.sub.2O.sub.3 32.5% CaO 1.4% TiO.sub.2 1.14% MgO 0.14 S 0.01% P 0.011%

[0134] B. Quartzite0.54 tons, size 25-60 mm

TABLE-US-00033 SiO.sub.2 97.5% Al.sub.2O.sub.3 1.2% Fe.sub.2O.sub.3 0.7% CaO 0.4% (MgO + TiO.sub.2 + P.sub.2O.sub.5 + S) <0.2% - balance

[0135] C. Iron turnings0.118 t, size 5-30 mm [0136] Fe.sub.total98.6% [0137] Si, Al, Cbalance

[0138] D. Vanadium pentoxide briquettes (V.sub.2O.sub.5) 0.15 tons, size 10-30 mm

TABLE-US-00034 V.sub.2O.sub.5 95.0% SiO.sub.2 0.3% Fe.sub.2O.sub.3 0.5% Al.sub.2O.sub.3 0.5% CaO 0.2% K.sub.2O + Na.sub.2O 0.4% P.sub.2O.sub.5 0.09% Ignition losses 3.01%.

[0139] At the end of the melting process is obtained a FeSiAl alloy with vanadium with the following average composition (mass-%):

TABLE-US-00035 Si 54.0 Al 18.5 V 7.4 Ca 1.0 C 0.21 Ti 0.60 P 0.007 S 0.001 Fe balance.

EXAMPLE 6

[0140] This example presents a ferrosilicon aluminum alloy in the charge of which was added titanium as oxide material besides carbonaceous rock, quartzite and iron turnings (wooden chips if required).

[0141] FeSiAl Alloy with Titanium

[0142] A. Carbonaceous rock 2.88 tons, size >20-80 mm

TABLE-US-00036 Ash content (on dry mass) 53.7% Volatile matter (on dry mass) 17.5% Humidity 4.2% Ash composition: SiO.sub.2 63.5% Fe.sub.2O.sub.3 2.3% Al.sub.2O.sub.3 31.4% CaO 1.7% TiO.sub.2 0.95% MgO 0.023% S 0.011% P 0.009% (MgO + TiO2 + P2O5 + S) <0.2%-balance

[0143] B. Quartzite0.36 tons, size 25-60 mm

TABLE-US-00037 SiO.sub.2 97.5% Al.sub.2O.sub.3 1.2% Fe.sub.2O.sub.3 0.7% CaO 0.4%.

[0144] C. Iron turnings0.129 tons, size 5-30 mm [0145] Fe.sub.total98.6% [0146] Si Al, Cbalance

[0147] D. Rich titanium slag 0.26 tons, size 10-40 mm

TABLE-US-00038 SiO.sub.2 9.67% Fe.sub.2O.sub.3 16.8% Al.sub.2O.sub.3 3.60% TiO.sub.2 63.2% CaO 3.4% MgO 1.7% P.sub.2O.sub.5 0.008% V.sub.2O.sub.5 1.40% Humidity 1.0%.

[0148] At the end of the melting process is obtained a FeSiAl alloy with titanium with the following average composition (mass.-%):

TABLE-US-00039 Si 49.5 Al 18.7 Ti 7.7 Ca 1.4 V 0.2 C 0.22 P 0.007 S 0.001 Fe balance.

EXAMPLE 7

[0149] This example presents a refined ferrochrome (FeCr) alloy in the charge of which besides chrome ore and lime was added FeSiAl alloy as reducing material.

[0150] A. Chrome ore 2.29 t, size 5-15 mm

TABLE-US-00040 Cr.sub.2O.sub.3 49.5% FeO 11.2% SiO.sub.2 8.6% Al.sub.2O.sub.3 7.5% CaO 0.22% MgO 18.5% S 0.023% P 0.007% Ignition losses 4.45%

[0151] B. Lime1.3 ton, size 10-25 mm

TABLE-US-00041 SiO.sub.2 4.6% Fe.sub.2O.sub.3 0.3% Al.sub.2O.sub.3 0.5% CaO 90.1% MgO 2.4%; P.sub.2O.sub.5 0.1% Ignition losses 2.0%

[0152] C. FeSiAl0.5 ton, size 5-10 mm

TABLE-US-00042 Si 58.6 Al 19.2 Fe 20.32 Ca 0.74 Ti 0.85 C 0.28 P 0.01 S 0.001

[0153] At the end of the melting process is obtained a FeCr alloy with the following average composition (mass-%):

TABLE-US-00043 Cr 71.3 Si 1.45 Al 0.20 C 0.08 P 0.01 S 002 Fe balance.

EXAMPLE 8

[0154] The following example presents the process of production of one ton magnesium metal with the use of FeSiAl alloy as a reducing agent. The beginning of the process includes briquetting of crushed doloma (calcined lime dolomite) and FeSiAl with size 0.1-5 mm. The reducing process is running for 8 hours in a retort at 1,200 C. and vacuum 10.sup.2 atm.

[0155] A. Doloma1.7 ton, size 0.1 to 2.0 mm

TABLE-US-00044 CaO 50.3% MgO 35.5% SiO.sub.2 1.8% FeO 1.0% Al.sub.2O.sub.3 0.8% P.sub.2O.sub.5 0.03% Ignition losses 10.57%.

[0156] B. FeSiAl0.25 ton, size 0.1-5 mm

TABLE-US-00045 Si 77.8% Al 7.2% Ca 0.70% Ti 0.50% C 0.12% P 0.009% S 0.002% Fe balance

[0157] At the end of the smelting process is obtained a pure magnesium metal (99.9%) and slag.

LIST OF REFERENCES

[0158] 1 carbonaceous rock [0159] 2 bin (hopper) [0160] 3 vibration feeder [0161] 4 conveyor [0162] 5 crusher [0163] 6 screen [0164] 7 quartzite [0165] 8 bin (hopper) [0166] 9 vibration feeder [0167] 10 conveyor belt [0168] 11 crusher unit [0169] 12 screen [0170] 13 hopper [0171] 14 hopper [0172] 15 hopper [0173] 15a iron turnings [0174] 16 dosing strain-gage weighter [0175] 17 dosing strain-gage weighter [0176] 18 dosing strain-gage weighter [0177] 19 belt conveyor [0178] 20 transport equipment [0179] 21 Sderberg electrodes [0180] 22 cone [0181] 23 melting furnace [0182] B hopper [0183] H wood chips