Ferrosilicon Production

 

Ferrosilicon production is an energy-intensive, high-temperature smelting process. The core principle involves reducing silica in quartzite using carbon at elevated temperatures, then combining it with iron to form ferrosilicon alloy. This production process heavily relies on quartzite resources and electricity supply, with electric arc furnace smelting being the mainstream technology. The specific workflow comprises three core stages: raw material preparation, high-temperature smelting, and iron tapping treatment.

T.F Industrial Co., Ltd. currently operates 6 submerged arc furnaces, 10 medium-frequency furnaces, and a suite of advanced modern production equipment, including powder preparation lines and core wrapping lines. We can provide you with high-quality products. Click the button below for detailed information.

 

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Chemical Composition	Si Fe Al Ca C P S
Size	10-50mm, 10-70mm, 10-100mm or as client's requirement
Packaging	1MT/bag or as per client's requirement
Supply Capacity	2000MT/month
Minimum Order Quantity	25MT

 

 

Stage 1: Raw Material Preparation

Silica Rock (SiO₂): The primary source of silicon and a key raw material affecting ferrosilicon purity.

SiO₂ content ≥97%. Crush silica rock into 50-100mm chunks. Particles too small may be carried away by gas flow, while larger ones undergo incomplete reduction.

Coke (C): Reducing agent and fuel, supplying carbon and heat for the reaction.

Fixed carbon content ≥85%, ash content ≤10%, volatile matter ≤3%.

Iron (Fe): Provides iron elements to alloy with silicon.

Remove oil and rust from scrap steel surfaces. Crush iron ore into 20-30mm pieces to ensure uniform iron element participation in the reaction.

 

Stage 2: High-Temperature Smelting

Ferrosilicon smelting occurs in an electric arc furnace, where the intense heat generated by electrodes provides the necessary thermal energy for reactions. This constitutes the core of the entire production process.

• Charging and Arc Initiation: Pre-treated silica, coke, iron source, and lime are mixed in specific proportions and charged into the furnace through the top. Simultaneously, three graphite electrodes are inserted into the furnace. Upon energization, an electric arc forms between the electrodes and the charge, initiating heating.
• Reaction Progression: As temperatures rise, the coke first burns to provide initial heat. Subsequently, the silica undergoes carbon reduction, yielding silicon and carbon monoxide (CO). The reduced silicon then combines with iron to form ferrosilicon, which gradually sinks to the furnace bottom. Impurities react with lime to form slag, which floats on the surface of the ferrosilicon.
• Parameter Control: Three critical parameters require real-time monitoring throughout the smelting process: current and voltage, furnace pressure, and charge level height.

 

Stage 3: Iron Tapping and Post-Processing

When a sufficient amount of ferrosilicon accumulates in the furnace, iron tapping and post-processing can commence.

• Iron Tapping: Open the tapping port at the bottom of the electric furnace. The molten ferrosilicon flows out under gravity through the flow channel into the cast iron mold. Slag is discharged separately through the slag outlet. The slag can be recycled for producing cement or insulation materials.
• Cooling and Crushing: Liquid ferrosilicon cools naturally to room temperature within the casting molds, forming lump ferrosilicon. These lumps are then crushed to the particle size specified by the customer.
• Inspection and Packaging: The crushed ferrosilicon undergoes composition testing. Qualified products are packaged in ton bags, while non-conforming material is returned to the furnace for remelting.

 

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