AP22683270 – « Development of technology for smelting manganese ferroalloys using non-conditioned iron-manganese raw materials»

Development of technology for smelting manganese-containing ferroalloys using unconditioned iron-manganese raw materials. The study solves the problem of recycling non-conditioned iron-manganese raw materials and carbon waste.

The chosen direction allows to solve the problem of utilization of carbon and silica raw material waste, and also to obtain the melting indicators of ferroalloys at a much better level than using traditional expensive carbon reducers.

In addition to utilization of undemanding small fractions of carbon and silica raw materials, this direction allows to additionally solve the following tasks:

– improvement of the quality characteristics of the produced product;

– increasing the technical and economic indicators of silicon ferroalloy smelting production due to optimization of the composition of charge materials.

In the case of the Republic of Kazakhstan, relatively low technological indicators of smelting ferrosilicon and ferrosilicomanganese alloys using traditional types of carbon reducers are prerequisites for project development.

It is recommended to use carbon composite materials made from coke, semi-coke and low-ash coal with additives of active siliceous materials as a carbon deoxidizer. At the same time, there is an opportunity to increase the specific electrical resistance of the mixture of charge materials, the power of electric furnaces, the rate of recovery of silicon and the technical and economic indicators of smelting

1) Akhmetov Begzat – master of technical sciences, researcher at the Department of Science and Innovation, project manager.

2) Nurumgaliyev Assylbek – Doctor of Technical Sciences, Professor of the Department of Metallurgy and Materials Science, domestic scientific consultant.

Scopus ID: 10042501900

Researcher ID: AAF-9195-2021

https://orcid.org/0000-0002-8782-9975

At least 2 (two) articles on the results of the implementation of scientific and (or) scientific and technical projects in the first three quartiles by the impact factor in the Web of Science database or at least 2 (two) articles in the journals with at least 50 percentile by CiteScore in the Scopus database and quality assurance in the field of Science and higher education 1 (one) article is published in domestic publications and (or) peer-reviewed foreign publications recommended by the committee;

Publication of monographs, books and (or) chapters in the books of foreign and (or) Kazakh publishing houses based on the results of scientific research is not considered.;

The possibility of patenting the obtained results in Kazakhstan or Eurasian patent bureau is not considered;

The development of scientific and technical, design documentation based on the results of scientific research is not considered;

The results of scientific research are promising, will be submitted to research projects for further grant funding and will be proposed for implementation in domestic ferroalloy plants in the future. The main results of the work will be published in international conferences, as well as peer-reviewed foreign or domestic publications presented in the metallurgical industry, and therefore will be accessible to the scientific community.;

The target consumers of the obtained results can be ferroalloy factories of Kazakhstan (JSC Kazchrom “TUK”, “Temirtau Metallurgical Plant” LLP, “KSP Steel” LLP, etc.), as well as interested companies in the coal processing industry.

The research is innovative in terms of increasing the technical and economic performance of smelting manganese-containing ferroalloys. At the same time, the problem of the use of iron-manganese raw materials, as well as the utilization of carbon raw materials, i.e., recycling, will be solved.

The application and commercialization of scientific results will be at a very high level. The technology of smelting manganese-containing ferroalloys using briquettes is of interest to ferroalloy plants and enterprises.

The expected economic efficiency when using the technologies developed in the ferroalloy industry consists in reducing the cost of production while increasing the productivity of electric furnaces. The cost reduction of the product is carried out due to the use of briquettes made from raw materials containing infertile iron-manganese. Productivity increase will be a consequence of increasing the power of electric furnaces due to the required electrophysical properties of briquettes.

Environmental efficiency during the implementation of the scientific project and the introduction of technologies developed in industry will consist of the use of non-conditioned iron-manganese materials, their involvement in metallurgical redistribution. Accordingly, the environmental load will be reduced in mining enterprises and nearby areas.

In the scientific and technical plan, a scientific base for the use and preparation of briquettes will be developed. The scientific and technical efficiency of the scientific project corresponds to the national project “Technological breakthrough due to digitization, science and innovation” and is aimed at the development of mining, coal processing and ferroalloy enterprises of the Republic of Kazakhstan.

When using developed technologies for melting manganese-containing ferroalloys using experienced briquettes, the multiplicative effect consists not only of increasing the power of electric furnace units, but also of increasing the output of leading elements and, accordingly, increasing the qualitative characteristics of the melted product.

New non-conventional ferro-manganese raw materials processing enterprises will create social and economic impact.

In the implementation of the project, a new software complex will be used for thermodynamic modeling of technological processes, which will significantly reduce the number of experiments required for the development of technologies for smelting manganese-containing ferroalloys.

Thermodynamic modeling allows predicting qualitative and quantitative indicators of reduction reactions, the distribution of elements in metallurgical phases under high temperature conditions of melting manganese-containing ferroalloys, as well as reducing time-consuming experiments in solving important technological problems based on the use of new software complexes with expanded databases.