The main raw materials for ferrosilicon production are silica (quartz stone), coke, and steel scrap (or waste steel). These materials are proportionally mixed and smelted at high temperature in a submerged arc furnace, producing ferrosilicon.
1. Silica – Provides Silicon Element
Silica is the primary source of silicon in ferrosilicon and plays a decisive role in determining product quality and yield.
Main component: Silicon dioxide (SiO₂)
The purity of SiO₂ must be above 97%, as lower impurity content minimizes undesirable reactions during smelting.
Key requirements:
High hardness and heat resistance: Must withstand temperatures above 1800°C in the furnace without softening.
Dense structure with low porosity: Prevents excessive air permeability that could lead to heat loss during smelting.
Common types: Natural quartzite and vein quartz are typically used. They must be crushed, screened, and processed into suitable particle sizes before being fed into the furnace.
2. Coke – Provides Carbon and Heat
Coke acts both as the reducing agent for silica and as the main fuel during smelting.
Reduction function: Fixed carbon in coke reacts with silica (SiO₂) to produce silicon (Si) and carbon monoxide (CO).
Heating function: Coke combustion releases large amounts of heat, maintaining the high-temperature environment required for continuous reduction reactions.
Key requirements:
- High fixed carbon content to ensure strong reduction ability and sufficient heat generation.
- Low ash content to avoid introducing impurities (such as alumina or iron oxide) that could lower ferrosilicon purity.
- Appropriate particle size (typically 10–25 mm) to ensure proper gas permeability and avoid excessive combustion losses.
3. Steel Scrap or Waste Steel – Adjusts Iron Content
Steel scrap or waste steel is mainly used to adjust the iron content in ferrosilicon and to improve furnace operation.
Main component: Iron (Fe)
The scrap used should have high purity, typically sourced from clean waste steel or machining chips, free from oil, rust, or other contaminants.
Key functions:
Composition control: Proper addition of steel scrap adjusts the iron content of the product within the standard range (generally 10%–20%, depending on the ferrosilicon grade).
Improved smelting conditions: Adding steel scrap reduces the electrical resistance of the charge, allowing electrodes to penetrate more effectively, ensuring uniform current distribution and enhancing smelting efficiency.
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