Ferroalloys are alloys of iron with other elements like manganese, chromium, or silicon. They are produced through carbothermic reduction in open arc or submerged arc furnaces. Major ferroalloys include ferromanganese, silicomanganese, ferrosilicon, and ferrochrome. Ferroalloys are added to molten steel to improve properties like strength and corrosion resistance and have applications in industries like automotive, transportation, and construction. The ferroalloys industry is expected to grow due to increasing demand from the global steel sector and adoption in emerging technologies.

1. PRODUCTION OF FERRO
ALLOY
SAGAR CHAKRABORTY
M.E. METALLURCAL ENGINEERING
JADAVPUR UNIVERSITY
ROLL. NO. -002211302007

2. Content
 Introduction of Ferro alloy
 Production Process of Ferro alloy
 Classification of Ferroalloy Processes by Reductant Type
 CO2 emission
 Main ferroalloys
 Types of Ferro Alloys
 Complex ferroalloy
 Uses Of Ferroalloy
 Application
 Future market
 Conclusion
 References

3. What is ferroalloy?
 The word ferroalloy refers to an alloy of iron containing a
significant proportion of one or more other elements like
silicon, manganese, chromium, aluminum, or titanium. The
main applications of ferroalloys occur in the steelmaking
process

4. Production of ferroalloy:
 Ferroalloys are produced generally by two methods :
I. in an open arc furnace
II. In an submarged arc furnace.
All high carbon alloys are produced in submerged arc furnace where the arc is submerged in the
charge.
for low and medium carbon alloys open Arc furnace are used
Blast furnace production continuously decreased during the 20th century, whereas the electric arc
production is still increasing. Today, ferromanganese can be still efficiently produced in a blast
furnace, but, even in this case, electric arc furnace are spreading. More commonly, ferroalloys are
produced by carbothermic reaction, involving reduction of oxides with carbon (as coke) in the
presence of iron. Some ferroalloys are produced by the addition of elements into molten iron.

5. Blust furnace production
 Ferro manganese can be manufactured in blast furnaces much
more economically compared to submerged arc furnaces. Some
modifications will be required in the design of conventional blast
furnaces for production ferro manganese.

6. Open arc furnace
 In these furnace, where arc is open, normally ore and
lime are melted together in low carbon Ferro Chrome
production. The liquid slag is allowed to react with
silicon reducer in the ladders. Hydraulic system is
different and all the electrode lifted at a time for the
movement of furnace. Furnace can be tilting and
travelling type.

7. Submerged Arc Furnace for production
of ferroalloys
classification of submerged Arc furnace
1. open furnace
2. closed furnace
3. semi closed furnace

8.  Open type furnace-
Most of the Furnace are open type with the Furnace top
exposed the reactions gases generated in the Furnace. due
to reductions reactions of oxides of ores with carbon are rich
in carbon monoxide. the later burns at the surface of
furnace top of carbon dioxide.
there are advantage also with this type of furnace.
1. Furnace conditions monitoring is easier.
2. Top conditions can be observed continuously.
3. Charge level can be kept as per requirement.
4. Constant poking of charge with stocking car can help in
release of gases.

9.  Closed typed furnace-
In closed furnace, the biggest advantage is conservation of
energy. Normally open top furnace are used for Ferro alloys
smelting however in view of high calorific value of furnace
gas comprising with 80 to 85% carbon monoxide, and to
recover the energy, closed top furnace consisting of a domes
roof has become popular.
Semi closed furnace-
Moderation of closed furnace

11. Classification of Ferroalloy Processes by
Reductant Type
Reduction by Carbon (Carbothermal Processes)
 In these processes, carbon is the main reductant of the metal oxides. The
overall reaction can be represented as MeO2 + yC=Me +MeCz + CO
Reduction by Silicon (Silicothermal Processes)
 Silicon reduction of metals from their oxides occurs with the formation of
silicon-rich metal melts MeO2 + Si=½Me+ Si + SiO2, and in some cases metal
silicides might also form if they are stable at the reaction temperatures.
Reduction by Aluminum (Aluminothermal Processes)
 Reduction by aluminum proceeds with the reaction MeO2 + (2x/3)Al=Me +
(x/3)Al2O3, which is accompanied by a significant exothermal effect.

12. CO2 Emissions from Ferroalloys Production
 Ferroalloys production is an energy-intensive industry with a high
consumption of electricity but only a moderate consumption of coke and
minor consumption of other fuels and reductants. This affects direct CO2
emissions.
only for direct emissions from the combustion of carbon when coke and
eventually coal are used for reduction as well as from electrodes consumption.
One has to adding direct emissions generated in electricity production so ,
depending on the method of electricity generation, the indirect CO2 emissions

13. The main ferroalloys are:
 FeAl - ferroalluminium
 FeB – ferroboron– 12–20% of boron, max. 3%
of silicon, max. 2% aluminium, max. 1%
of carbon
 FeCe – ferrocerium
 FeCr – ferrochromium
 FeMg – ferromagnesium
 FeMn – ferromanganese
 FeMo – ferromolybdenum – min. 60% Mo, max.
1% Si, max. 0.5% Cu
 FeNb – forroniobium
 FeNi – ferronickel(and nickel pig iron)
 FeP – ferrophosphorus
 FeSi – ferrosilicon – 15–90% Si
 FeSiMg – ferrosilicon magnesium (with Mg 4 to
25%), also called nodulizer
 FeTi – ferrotitanium – 10..30–65..75% Ti, max.
5–6.5% Al, max. 1–4% Si
 FeU – ferrouranium
 FeV – ferrovanadium
 FeW – ferrotungsten

14. Types of Ferro Alloys
Ferroalloys are classified into two main categories,
1. Bulk ferro alloys and
2. Noble ferro alloys.
Bulk ferroalloys is majorly used in stainless steel & carbon steel.
Most of the noble ferroalloys are made from rare-earth minerals and are
expansive to produce as compared to bulk ferroalloys.

15. Bulk Ferroalloys
 Ferromanganese
 Silicomanganese
 Ferrosilicon
 Ferrochrome
 Chargechrome

16. COMPLEX FERROALLOYS
 Complex ferroalloys and master alloys are used in steel and special alloys
manufacturing for alloying (and composition adjustment) and refining
(oxygen, sulphur, etc. removal) purposes. Historically, complex ferroalloys
have been made by fusing (smelting) several ferroalloys and then tapping and
casting, and classifying them into relevant sizes. However, this method is not
very economicdonce produced, ferroalloys must be again heated, melted, and
processed. This leads to substantial energy and material losses and possibly
more environmental pollution.

17. Uses Of Ferroalloy
 FERRO SILICO MANGANESE
Melting Range -1130-1230°C
SPECIFIC GRAVITY - 6.35
Used mainly in low carbon grades of steel due to the low carbon content of the
alloy, nominally C 1.5%-2.0%, or where specific alloying characteristics are
required.

18.  FERRONIOBIUM-
Melting Range -1500-1550 C
SPECIFIC GRAVITY –8.2
Also called Columbium and used by steel makers as grain refiner in HSLA
steels and as a carbide former in austenitic stainless steels.
 FERRO PHOSPHORUS
Melting Range -1250-1350°C
SPECIFIC GRAVITY -6.4
Used in the production of phosphoric irons and certain free cutting
steels, supplied in lumpy or crushed form, typically 25% P with controlled
Si contents 1% and 2% max.
 FERRO SELENIUM
Melting Range- 480-940°C
SPECIFIC GRAVITY - 6.35
Available as the 50/50 alloy, normally in the lumpy or crushed form. Used
in the production of free cutting stainless steel.

19.  FERRO SILICON ZIRCONIUM
Melting Range -1250-1340°C
SPECIFIC GRAVITY -3.5
Typical analysis is 50% Si, 35% Zr. Used as deoxidant in steel castings or in
certain steels where a low residual aluminium is required.
 FERRO TUNGSTEN
Melting Range - 1650-2100°C
SPECIFIC GRAVITY - 15.4
This alloy is mainly used in high speed and tool steels. Owing to its high
melting point the alloy is almost always added to the furnace rather than
to the ladle.

20. Applications of Ferro alloy
 The main applications of ferroalloys occur in the steelmaking process. They
are added to steel to improve properties like strength, ductility, and fatigue
or corrosion resistance.

21. FUTURE OUTLOOK FOR THE FERROALLOYS
INDUSTRY
 The increasing demand for ferroalloys across the global steel industries, the
automotive and transportation industries are expected to boost global market
demand. The global ferroalloys market is expanding due to its use in the
automotive, transportation industries and vehicle as well as technological
advancements.

22. CONCLUSION
 Ferroalloys development and production have been boosted together with the
rapid increase in steel and alloys processing. It soon became very clear that
ferroalloys require new techniques as the then existing blast furnace or
steelmaking converter technologies were not capable of fulfilling the
demanding needs of industry. As the requisite electrical technology was
developed in parallel, at the beginning of 20th century ferroalloys had caught
up with electrometallurgy and this has continued until today.

23. References
 1/ 1Rudolf Fichte. "Ferroalloys". Ullmann's Encyclopedia of Industrial
Chemistry. Weinheim: Wiley-VCH. doi:10.1002/14356007.
 2/ Corathers, Lisa A.; et al. (October 2010). Ferroalloys (PDF). Minerals
Yearbook 2008 (Report). Vol. I. U.S. Geological Survey. pp. 25.1–25.14.
doi:10.3133/mybvi. Retrieved 2019-10-18.
 3/ Bedinger, George M.; Corathers, Lisa A.; et al. (October 2016). Ferroalloys
(PDF). Minerals Yearbook 2014 (Report). Vol. I. U.S. Geological Survey. pp.
25.1–25.3. doi:10.3133/mybvi. Retrieved 2019-10-18.
 4/ Kudo, Akira. Japanese-German Business Relations: Co-operation and
Rivalry in the Interwar. pp. 89–108. Archived from the original on 2014-10-20.
Retrieved 2014-12-21
 5/ Ferronickel – Properties, Applications". AZoM.com. August 21, 2013