Ferrosplav – what is it? Plants of ferro-alloys

Metallurgical industry is the high-tech industry, which requires not only minerals, but synthetic products or additives that improve the performance of metals. For the production of steel using alloys of iron with certain components. The resulting compound – this is the ferro-alloys.

What is it?

Ferroalloy – a material needed for the metallurgical industry, used for alloying, deoxidation, refining ferrous and nonferrous metals. Based on Ferroalloy an alloy of iron (Fe, ferrum) with additives (manganese, potassium, molybdenum, silicon, etc.). Production takes place in special units.

To the present time for the manufacture of the material used is an alloy of iron with more than twenty items. New research and industrial needs, demonstrate the increase in the number of connections.

The Appointment of ferro-alloys

In the steel industry ferro-alloys are used for alloying, which allows you to get more than 2.5 thousand different brands of steels. Improved types of steel are used in mining, metallurgy, chemical, construction, defense industry and other industries. Ferroalloy – it is additive in the metal, which is introduced to modify the properties of the final material. Correction the quality of steel allows to improve mechanical properties, resistance to extremes of temperature or aggressive chemical environment. The final properties of the material will depend on composition, which was introduced in the period of melting metal.

Production of ferro-alloys and their continued use allows to obtain alloy steels with modified functionality, e.g., instrumental or non-magnetic material. The deoxidation of steel by using ferro-alloys is essential for binding and output in the slag of the oxygen from the crowd. There are used compounds of iron with silicon, titanium, aluminium, etc.

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Also, Ferroalloy – it is a modifier for steel or cast iron, designed to reduce grain, improve the structure of the material and influence the strengthening of mechanical properties. For obtaining modifying additives iron connect with several elements, for example calcium+silicon, iron+manganese, iron+silicon+magnesium etc.

Raw materials

The Ferroalloy Production starts with the raw materials, which is the ore rich in a particular group of items. For example, ferrosilicon and ferrochromium used ore concentrate and ferrotungsten ferrotitanium or raw material is concentrate. The technological process includes a step of recovery of metal oxides entering the compound. The catalyst is iron or its oxides. The recovered item obtains the conditions for the stable form and their absence for the reverse oxidation. Metallurgical industry at the present stage the most commonly uses method of electrothermal production of ferro-alloys, which is based on reduction reaction. Melting steel with the addition of alloys reduces the temperature in the furnace, thereby reducing the energy intensity of production.

Types of ferro-alloys

Currently, the world production of ferro-alloys is 16.5 million tons a year. The number of items of hundreds of brands, which fully meets the production needs of all kinds of steel (ordinary, special, structural). Russian share in world production is 12,7 %, the leading position is occupied by China, USA, Japan. Ferroalloy – this is one of the most popular types of products, its production is a promising direction of development of the industry.

The Main types of ferroalloys:

• Ferrosilicon.
• Silico-calcium.
• Ferromanganese.
• Ferro-chrome (medium carbon, low carbon, resplendency).
• Silichrom.
• Ferrovolfram.
• Ferromolibden.
• Ferrovanadij.
• Ferrotitan.
• Ferronor.
• Exothermic alloys.

Ferroalloy industry

The Ferroalloy industry in Russia up to 1917 was represented by a single plant located in the Urals. The power plant consisted of two kilns at 250 kW. In 30-e years, was commissioned 4 plants: Lipetsk, Chelyabinsk, Zaporozhye (Ukraine), "Zestafoni" (Georgia).

In the period from 1942 to 1945 was built and launched Kuznetsk, Aktobe, Klyuchevskii Ferroalloy facilities. In the postwar years were phased into operation Serovskiy Zavod (1956), Stakhanov Ukraine (1962), Nikopol (Ukraine, 1966), ermakovskaya in Kazakhstan (1968). Introduced capacity meets the needs of the domestic market and allowed to enter the foreign market with a competitive offer. Total production of ferro-alloys to the time of the collapse of the USSR amounted to 6 million tons per year. In Russia today operates ten factories specializing in the production of ferroalloys. The largest of these is the Chelyabinsk metallurgical plant.

The Aksu plant in Kazakhstan

The Aksu ferroalloys plant located in the Pavlodar region of Kazakhstan. Prior to 1995 bore the name of Yermak Ferroalloy plant, date of entry inoperation – 1966. In 1995 the company was sold to Japanese company Japan chrome Corp., in the same year, she became part of the Corporation "include". Total annual production is about million tons. Currently, the company is one of the world leaders in the production of alloys. Consumed energy capacity is 600 megawatts. The main gross domestic product – chromium, manganese, silicon alloys.

The Production capacity

• Four smelter.
• Twenty-six electric furnaces with the capacity from 16.5 to 63 MVA.
• Two preparatory workshop.
• Shop the processing of slag.
• Mechanical Repair shop.
• Automotive and railway shop.

The Total workforce – 6,000.

Novokuznetsk plant

In 1942 began producing ferroalloys in Novokuznetsk. In 1992 the enterprise changed the form of government, becoming a joint stock company. The first change of ownership occurred in 2000, the management company was a group of MDM. And since 2010, control of the plant carries out the Ural-Siberian metallurgical company.

Principal products are designed for deoxidation, alloying of steel with ferrosilicon. For machine-building industry issued the modifiers used in the smelting of iron. A new kind of production has become silica fume is used to manufacture steel and prakosa involved in the process of steel casting.

Klyuchevskoy plant

Klyuchevskaya Ferroalloy plant was established on the basis chromological factory in 1941. Today is the CIS only enterprise, producing more than 30 kinds of ferro-alloys, ligatures. Part of the company «Midura Groups”.

In the nomenclature of products includes:

• Silico-calcium with the addition of vanadium, zirconium, titanium, aluminum.
• Siliconindia, ferroniobium, silico-calcium, ferrotitanium.
• Modifier ferrosilicozirconium with magnesium content.
• Alloys & ndash; on the basis of niobium and Nickel and rare earth metals.
• Slag etc.

The current production is used in the deoxidation, alloying, degassing of steel and its alloys, and also as modifiers of iron.

Nikopol ferroalloys

The First phase of the plant was started in 1966. Since 1968, the company was considered the largest in Europe. The greatest blossoming and full capacity utilization Nikopol plant of ferroalloys reached in 1985-1990. After that, production steadily declined. Today, the factory – recognized as industry leader in Ukraine. Due to the difficult economic situation is on the verge of closing.

Products:

• Ferrosilicomanganese.
• Ferromanganese.
• Weight of electrode.
• Fluxes.
• Slag, abrasives, crushed.
• Fair trade.

Plant in Bratsk

Bratsk Ferroalloy plant is located in Irkutsk oblast and is the largest producer of ferrosilicon East Siberian region. The plant was established on the basis of one of the shops Bratsk aluminum plant. The need of the enterprise was due to domestic demand in semiconductors, solar, electronics. The main product of the enterprise is ferrosilicon with high silicon content – up to 75%. The production was organized in 1998. In order to ensure own raw material BFZ develops the Uvat quartzite Deposit ores. The industrial complex receives electricity from nearby Bratsk hydroelectric power station, which significantly reduces the cost of production, over a third of which is being implemented among enterprises, the parent company, “Mechel”.

Serovskiy plant

Serov ferroalloys produced for over 50 years. The plant is the second production in Russia. Main products – the ferrochrome (high carbon, medium carbon, low carbon, Ferrosilicochrome). The first phase of the refinery was launched in 1961. Today is part of the company «CMAC”.

The Ferroalloy Plant is located in Sverdlovsk region (Serov), the annual production capacity is about 200 thousand tons of finished products. The company produces a wide range of master alloys on the basis of low-carbon ferrochromium obtained by mixing the melts. Responding to the needs of the domestic metallurgical market, the company has mastered the production of ferrosilicon. The products are supplied to many foreign markets and domestic enterprises.

Aktobe plant

The Plant is located in Aktobe city (Kazakhstan). The first ton of ferroalloys was produced at a plant in 1943. Main products – ferroaluminium, ferromanganese, ferrochromium, ferrosilicon, terracing, non-ferrous metals and their alloys, alloys for catalytic processes.

Aktobe plant of ferroalloys per year and produces more than 300 thousand tons. In addition, the company manufactures concentrates for metallurgical industry (elementonly, zircon, rutile). The plant is one of the world leaders in production inindustry. Management company – TNC "include".

Factories of ferro-alloys in Russia and CIS

Enterprises:

• Alapayevsk metallurgical plant, production – ferromanganese.
• Kosogorskogo MTZ in Tula, products – pig iron, ferromanganese.
• The Serov plant, the products – ferrochromium.
• Brotherly factory, the main products – ferrosilicon.
• Ryazan plant, the main products – ferromolybdenum, ferrovanadium, ferrotungsten, the company produces alloys of rare metals.
• The Tikhvin plant, production – ferrochromium.
• Kuznetsk factory of ferroalloys (ferrosilicium).
• Klyuchevsky plant produces rare alloys – ferroboron, ferroni, ferrotitanium etc.
• Chelyabinsk IEC – the industry leader. Manufactured products – ferromanganese, ferrosilicon, ferrosilicochromium, silico-calcium, etc.
• Kingisepp plant (ferromanganese, silicomanganese).

Companies:

• Zaporizhia plant for the production of ferro-alloys produces ferrosilicon, manganese metal, ferroalloys, etc.
• Nikopol, production – ferrosilicomanganese, ferromanganese, etc.
• Plant Stakhanov in the Luhansk region, product types – ferrosilicomanganese, ferrosilicon, ferromanganese.
• Donetsk plant of ferroalloys, the main products – ferroaluminium.

At the beginning of 2017 Ukrainian enterprises almost ceased their activities due to the civil war and deep economic crisis in the country.

Enterprises of Kazakhstan:

• Aktobe plant of manufactured products is based on chromium, manganese, silicon alloys.
• The Aksu ferroalloys plant produces ferromanganese, ferrochromium, etc.

Georgian manufacturers:

• Consultant to the factory, produced kinds of ferro alloys – ferromanganese.