Parameters Affecting Energy Consumption for Producing High Carbon Ferromanganese in a Closed Submerged Arc Furnace

Abstract

The power consumption is considered to be the most important factor affecting the production cost of ferromanganese alloy. Different parameters affecting the energy consumption for industrial production of high carbon ferromanganese HCFcMn were investigated in a closed submerged arc furnace. The analysis of industrial data revealed that the most energy-consumed factorswcre the direct reduction by solid carbon, Boudouard reaction, metal and slag formation, and dccompositionof fluxing materials (limestone and dolomite). To reduce the energy consumption and minimize the energy losses in the production process of HCFcMn, it was recommended to use Mn blend with minimum Mn to Fc ratio of 6 and lower SiO2 content or higher basicity. The added cokcmust be adjusted according to the material balance to prevent the over-coke and to minimize the highly endothermic “Boudouard reaction”. In addition, it was recommended towork at basic slags with the ratio of (CaO + MgO) to SiO2 equal to 1. 0–1. 2 instead ofmuch higher slag basicity. Furthermore, the mass losses had to be minimized through adjusting the handling and charging process and to take care of all metal produced.