АР13068023 – «Research and Development of Steel Processing Technology With Complex Ligature Fe-Si-Mn-Al»

Global quality standards are increasing every year, against its background, manufacturers in competition seek to reduce the cost of a metal product by saving energy resources and materials used, without losing quality. Much attention is paid to the production of steel with a reduced content of non-metallic inclusions. Non-metallic oxide inclusions during steel processing have sharp edges that serve as the center of stress concentration. The impact of this factor should be minimized as much as possible. To reduce the oxygen concentration in steel, various deoxidation methods are used. Deoxidation is a key step in improving the quality of steel.

The production of complex ligatures requires the use of new types of raw materials and materials, and the maximum use of all its components makes it possible to process technogenic substandard raw materials and to develop low and waste-free technologies for producing ferroalloys.

The proposed technology for producing new ligatures based on Fe-Si-Mn-Al is based on the use of high-ash coal, which is not used in the power industry because of the high ash content and substandard high-silica and ferromanganese ores, unsuitable to produce standard grades of manganese ferroalloys.

Complex ligatures based on Fe-Si-Mn-Al will have a few advantages over standard ferroalloys. The advantages of complex deoxidizers are especially clearly manifested in the kinetics of the deoxidation process and the purification of metal from deoxidation products. The processed metal will contain the least number of non-metallic inclusions

1) Kelamanov Bauyrzhan – candidate of technical sciences, associate professor, project leader.

Scopus ID: 25655181100  

Researcher ID: ABE-5597-2021  

https://orcid.org/0000-0001-7646-9153

2) Zhuniskaliev Talgat– Doctor of Philosophy (PhD), senior researcher at the Department of Science, Innovation and International Cooperation, co-director of the project.

Scopus ID: 57218196497  

Researcher ID: AAG-6131-2021 

https://orcid.org/0000-0001-9757-0605

3) Mukhambetgaliev Erbol – Doctor of Philosophy (PhD), project executor.

Scopus ID: 57214103799 

https://orcid.org/0000-0001-8262-6565

4) Kuatbay Erbol – Doctor of Philosophy (PhD), project executor.

Scopus ID: 57218196966  

Researcher ID: ABE-5679-2021 

https://orcid.org/0000-0002-8400-3537

5) Makhambetov Erbolat – Doctor of Philosophy (PhD), project executor.

Scopus ID: 57189221884 

Researcher ID: ABF-3760-2021 

https://orcid.org/0000-0001-8613-9932

6) Erekeeva Gauhar – Master of Technical Sciences, project executor.

Scopus ID: 57611544700 

Researcher ID: AED-4479-2022 

https://orcid.org/0000-0002-7338-4469

7) Abdirashit Asylbek – Master of Technical Sciences, project executor.

Scopus ID: 57218196252 

Researcher ID: ABE-5588-2021 

https://orcid.org/0000-0003-0718-3041

8) Tushiev Tair – Master of Technical Sciences, project executor.

Researcher ID: CDM-7881-2022

9) Esmurat Mynzhasar – Master of Technical Sciences, project executor.

Based on the results of the implementation of a scientific and (or) scientific and technical project, 5 (five) articles will be published in peer-reviewed scientific publications in the scientific direction of the project, in Q1-Q3 quartiles by impact factor in the Web of Science database and (or) having a percentile according to Cite Score in the Scopus database 2 (two) not less than 50 (fifty), 1 (one) not less than 35 (thirty five) and 2 (two) articles in a domestic publication in the field of metallurgy recommended by COXON or equivalent publications , the postdoctoral student will be the corresponding author and/or the first author.

Based on the results of scientific research, the publication of monographs and books is not considered.

Possibilities of patenting the obtained results in a foreign, Kazakh or Eurasian patent bureau are being considered.

Based on the results of scientific research, the development of scientific, technical, design documentation is not considered.

The results of scientific research will be disseminated at international conferences, symposiums, various international technology exhibitions, publication of articles in peer-reviewed scientific publications in the scientific direction of the project and domestic publications in the field of metallurgy recommended by COXON or equivalent publications.

The target consumers of the new complex alloy will be the converter shop of Qarmet JSC, the shaped and foundry shop of KurylysMet LLP and other steel plants in Kazakhstan, near and far abroad.

The results of the study are promising in terms of improving the technological process of steel deoxidation. In this case, the most optimal chemical composition of the deoxidizer from manganese-containing ores and high-ash coals will be proposed. As a result of the study of the complex deoxidizer, a technological process for obtaining a complex deoxidizer will be proposed with the involvement of substandard manganese ores and high-ash coals that are not used for industrial purposes as charge materials.

The test results will be validated, a package of documents will be transferred directly to the scientific and technical department of ArcelorMittal Temirtau JSC co-financing this project and other production organizations, and, as necessary, recommendations will be issued on the implementation of technology for the production of complex deoxidizers containing Si-Mn-Al.

The social and economic effect of the project implementation will be significant: the complex deoxidizer will improve the quality of steel; increase the yield of finished products; launch of new enterprises to produce complex deoxidizers; development of small deposits of manganese ores; increase in demand for high-ash coals previously used only for domestic needs.

The environmental effect of the project will be from the implementation of the technology to produce complex deoxidizers from substandard manganese ores and high-ash coals, where all elements will be involved in the production of a new complex alloy. The scientific and technical effectiveness of the project is aimed at solving the national project of the Republic of Kazakhstan «Technological breakthrough through digitalization, science and innovation» and at improving the production of high-quality metal products.

The project will use modern software systems such as HSC Chemistry and Thermo-Calc, which will significantly reduce the number of experiments required to develop the production and use of a new complex alloy and steel deoxidation. HSC Chemistry allows you to simulate the process of obtaining a complex ligature under optimal conditions without additional energy costs and reduces material-intensive experimental studies, and Thermo-Calc can help in the preliminary selection of test conditions, allowing you to better target experiments to obtain the necessary data.

1) The physico-chemical properties of the charge materials were studied, thermodynamic modeling and laboratory tests were carried out for the smelting of the Fe-Si-Mn-Al master alloy. It was established that the phase composition of manganese ores is presented in the form: Mn2O3•MnSiO3, MnFe2O4, MnO2 and SiO2. The softening temperature of ores is in the range of 1070-1195℃. The electrical resistance of high-ash Saryadyr coal when heated is relatively high, which has a positive effect on the process of smelting the master alloy. According to thermodynamic data, it has been established that when smelting a master alloy, reduction processes and metal formation begin at a temperature of 1500℃. The phase composition of the alloy is presented in the form of intermetallic compounds Mn5Si3, FeSi, FeAl and FeAl3, which with increasing temperature (> 2000℃) intermetallic compounds decompose into independent phases in the form of free Si, Mn and Al. The most optimal condition for smelting Fe-Si-Mn-Al alloy from high-ash coals is a charge mixture with an excess of reducing agent (O/Stv = 1.16). In a 150 kVA ore reduction furnace, the fundamental possibility of producing Fe-Si-Mn-Al master alloy from high-ash coals and manganese ores of the Republic of Kazakhstan has been established. Test samples of the alloy were obtained with an average content, %: Mn 35.5; Fe 14.32; Si 38.49; Al 8.74. For the first time, a set of measures was carried out to select the optimal composition of charge materials for smelting the Fe-Si-Mn-Al alloy and the promising (optimal) composition of the Fe-Si-Mn-Al alloy for steel deoxidation was determined, %: Mn 25-40; Fe 5-15; Si 30-50; Al 5-12.

2) It was established that the phase composition of manganese ores is represented by braunite Mn2O3•MnSiO3, jacobsite MnFe2O4, pyrolusite MnO2 and quartz SiO2. Thermodynamic analysis showed that when smelting Fe-Si-Mn-Al master alloy using the carbothermic method, the most optimal condition is a charge mixture with an excess of a reducing agent (O/Stv = 1.16). The Fe-Si-Mn-Al alloy is presented in the form of intermetallic compounds Mn5Si3, FeSi, FeAl and FeAl3. Test samples of the alloy were obtained with an average content, %: Mn 35.5; Fe 14.32; Si 38.49; Al 8.74. The promising (optimal) composition of the Fe-Si-Mn-Al master alloy for steel deoxidation has been determined. The range of chemical composition of the alloy for steel deoxidation is within the range of %: Mn 25-40; Fe 5-15; Si 30-50; Al 5-12.

3) An ore-thermal electric furnace with six stages of secondary voltage regulation was used, which made it possible to fine-tune the parameters for the smelting process. It was determined that the optimal voltage for the process is 33.5 V (stage II), with a current strength of 2400-2800 A, which contributed to a more efficient smelting process. The smelting of the complex master alloy was carried out with the following composition of the charge, kg: coal – 20; manganese ore of the Bogach deposit – 8; quartzite – 2.53. The necessary experimental batch of complex master alloy was obtained for further use in steel deoxidation. Chemical composition of the complex alloy,%: Mn – 33.65; Si – 45.01; Al – 5.23 and Fe 10.68. The efficiency of the process is confirmed by high recovery rates of silicon, manganese and aluminum: Si – 69.59%, Mn – 82.78% and Al – 30.59%. 4) Technological instructions have been developed for obtaining a complex master alloy from high-ash coals and manganese ore.

Large-scale laboratory tests were carried out in a large-scale laboratory ore-smelting furnace with a capacity of 250 kVA. As a result, the optimal voltage for the process of smelting the complex alloy was determined – 33.5 V (II stage), with a current strength on the low side – from 2400 to 2800 A. The smelting of the complex alloy was carried out with the following composition of the charge, kg: coal – 20; manganese ore of the Bogach deposit – 8; quartzite – 2.53. The necessary experimental batch of complex master alloy was obtained for further use in steel deoxidation. Chemical composition of the complex alloy,%: Mn – 33.65; Si – 45.01; Al – 5.23 and Fe 10.68. The extraction of the leading elements of the complex master alloy was: silicon – 69.59%, manganese – 82.78% and aluminum – 30.59%. The total duration of the large-scale laboratory smelting of the complex master alloy was 6 days (144 hours).

1) Nurumgaliev, A., Makhambetov, Y., Kuatbay, Y., Yerekeyeva, G., Abdirashit, A., & Mynzhassar, Y. (2023). Study of softening temperatures of manganese ores in central Kazakhstan. Metalurgija, 62(2), 268-270. – https://www.scopus.com/record/display.uri?eid=2-s2.0-85162000914 (Scopus, 35th percentile).

2) Nurumgaliyev, A., Zayakin, O., Zhuniskaliyev, T., Kelamanov, B., & Mukhambetgaliyev, Y. (2023). Smelting of Fe–Si–Mn–Al Complex Alloy Using High-Ash Coal. Metallurgist, 1-9. – https://doi.org/10.1007/s11015-023-01609-x (Scopus, 42th percentile).

3) Нурумгалиев А.Х., Заякин О.В., Жунискалиев Т.Т., Келаманов Б.С. Мухамбеткалиев Е.К. Выплавка комплексной лигатуры Fe–Si–Mn–Al с использованием высокозольного угля. МЕТАЛЛУРГ, (2023), №8 с. 84-89

4) Nurumgaliyev, A., Zhuniskaliyev, T., Shevko, V., Mukhambetgaliyev, Y., Kelamanov, B., Kuatbay, Y., … & Volokitina, I. (2024). Modeling and development of technology for smelting a complex alloy (ligature) Fe-Si-Mn-Al from manganese-containing briquettes and high-ash coals. Scientific Reports, 14(1), 7456. – https://doi.org/10.1038/s41598-024-57529-6 (Scopus, 92th percentile).

5) Kelamanov, B., Kyatbay, Ye., Yerekeyeva, G., Tushyev T. Theoretical and experimental modeling of the process of melting complex alloyed steels (Fe-Si-Al-Mn). Acta Metallurgica Slovaca, Vol. 30 No. 2 (2024)

6) Kuatbay, Ye., Nurumgaliyev, A., Makhambetov, Ye., Zhuniskaliyev, T., Abdirashit. A., Study of Physico-chemical Properties of High-ash Coal from the Saryadyr Deposit. Труды университета №3 (88), 2022

7) Нурумгалиев А.Х., Жүнісқалиев Т.Т., Каган Б., Тушиев Т.Р., Мыңжасар Е.А. Термодинамическое моделирование процесса выплавки комплексной лигатуры Fe-Si-Mn-Al. Наука и техника Казахстана, №2, (2024).