This handbook gathers, reviews and concisely presents the core principles and varied technology involved in processing ferroalloys. Background content in thermodynamics, kinetics, heat and mass transfer is accompanied by an overview of electrical furnaces theory and practice as well as sustainability issues. The work includes detailed coverage of the major technologies of ferrosilicon, ferronickel, ferromolybdenum, ferrotungsten, ferrovanadium, ferromanganese and lesser known minor ferroalloys. Distilling the results of many years' experience in ferroalloys, Michael Gasik has assembled contributions from the worlds' foremost experts. The work is therefore a unique source for scientists, engineers and university students, exploring in depth an area which is one of the most versatile and increasingly used fields within modern metallurgy. - All-in-one source for the major ferroalloys and their metallurgical processing technologies, cutting research time otherwise spent digging through old handbooks or review articles. - In-depth discussion of the C, Si, Al-reduction, groups II-VIII of the periodic table, supporting analysis of metallurgical processing. - Contemporary coverage includes environment and energy saving issues.

This book outlines the physical and chemical foundations of high-temperature processes for producing silicon, manganese and chromium ferroalloys, alloys of molybdenum, vanadium, titanium, alkaline earth and rare earth metals, niobium, zirconium, aluminum, boron, nickel, cobalt, phosphorus, selenium and tellurium, iron-carbon alloys by carbon, silicone and aluminothermic methods. The chapters introduce the industrial production technologies of these groups of ferroalloys, the characteristics of charge materials, and the technological parameters of the melting processes. A description of ferroalloy furnaces is given in detail. Topics such as waste recycling, fines agglomeration technologies, and environmental issues are considered.

The process by which ore is converted to a ferroalloy contains a number of steps. These include mining of the ore; preparing the ore by processes such as crushing, screening, washing, grinding, or milling; and sometimes applying beneficiation processes such as flotation, followed by smelting and refining. This chapter describes the equipment used for the smelting of ferroalloys. The first section covers furnace technology and operation by discussing AC and DC furnaces, their electrical operation, electrodes, and related plant such as raw material handling systems, exhaust gas handling, and furnace crucibles, which includes the linings, and cooling of the furnace and the roof. The second section discusses the more important processing steps, which may be applied to the raw materials at the smelter prior to their smelting in the furnace. These include agglomeration by briquetting or the production of sintered pellets, sintering of ore, prereduction, and preheating. The third section describes the treatment of the product and slag after it leaves the furnace, whereas the final section provides a short description of other furnaces for ferroalloys production.

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. They are added to steel to improve properties like strength, ductility, and fatigue or corrosion resistance. Additionally, ferroalloys can have several other tasks, such as in refining, deoxidation, modification, and control of nonmetallic inclusions and precipitates. The production and role of ferroalloys are briefly introduced, both from a historical perspective and in light of current and future prospects. Examples of production figures, producers, and markets are presented. Recent developments and main drivers in ferroalloys processing, including energy saving, environmental issues, primary and secondary raw materials resources, and development trends in technology, are briefly discussed.

High carbon ferrochrome is one of the most common ferroalloys produced and is almost exclusively used in the production of stainless steel and high chromium steels. Production takes place primarily in countries with substantial chromite ore supply. Relatively cheap electricity and reductants also contribute to the viability of high carbon ferrochrome. The most common production technology utilized is submerged arc smelting in AC furnaces, although open arc smelting in DC furnaces is becoming increasingly common. A more advanced technology route that includes a prereduction step is only utilized at significant scale by one producer. Production processes have become more energy and metallurgically efficient by utilizing advanced processes such as prereduction, preheating, agglomeration of ore, and CO gas utilization. Recently installed plants display manageable risks in terms of environmental pollution and occupational health.

This unique and practical book provides quick and easy access to data on the physical and chemical properties of all classes of materials. The second edition has been much expanded to include whole new families of materials while many of the existing families are broadened and refined with new material and up-to-date information. Particular emphasis is placed on the properties of common industrial materials in each class. Detailed appendices provide additional information, and careful indexing and a tabular format make the data quickly accessible. This book is an essential tool for any practitioner or academic working in materials or in engineering.