The effect of different carbon reductants on the production of ferrosilicon 75% on an industrial scale in an electric arc furnace

Ferrosilicon production is based on the carbothermal reduction of silica and iron oxide in submerged electric arc furnaces. The reducing process of iron oxide and silicon oxide is carried out by the carbon contained in carbon materials such as coal, charcoal, semi-coke, and all types of coke. Based on its inherent and functional characteristics, the kind of carbon material can be effective in the ferrosilicon production process and furnace energy consumption. Therefore, in this work, which was performed by Iran Ferrosilice company, in a long period of 5 years, the effects of seven combinations of different carbon materials on the electrical and metallurgical performance of the process were investigated. The results showed that the minimum value of energy coefficient per ton (8.46 MWh/ton) was obtained using combination 5 (consisting of 55% coal, 30% semi-coke, 5% charcoal, and wood chips). The use of wood chips reduced the energy consumption by 3.03 MWh/ton. The composition consisting of 50% coal, 35% semi-coke, 15% charcoal, and wood chips had the highest Si% of 73.64% and the lowest Al% of 1.54%. Finally, by evaluating all the results, especially the reduction of energy consumption and recovery of Si, compound 5 was introduced as the optimal compound in the ferrosilicon production process.