Table Of Content

Proceeding of THE FOURTEENTH INTERNATIONAL FERROALLOYS CONGRESS Ukraine, Kiev, May 31-June 4, 2015 INFACON XIV Energy efficiency and environmental friendliness are the future of the global Ferroalloy industry Volume II Proceeding of THE FOURTEENTH INTERNATIONAL FERROALLOYS CONGRESS Ukraine, Kiev, May 31-June 4, 2015 INFACON XIV Energy efficiency and environmental friendliness are the future of the global Ferroalloy industry Volume II Energy efficiency and environmental friendliness are the future of the global Ferroalloy industry: Proceedings of the Fourteenth International Ferroalloys Congress INFACON XIV. (May 31-June 4, 2015, Kiev, Ukraine). - инфо о типографии ISBN ISBN ISBN Copyright @ 2015 Public Organization INFACON XIV. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any from or by any means, electronic, photocopying, microfilming, recording or otherwise without written permission of the copyright owner. These Proceedings contain original articles provided by authors. Any errors, omissions and grammatical inaccuracies are the responsibility of the original author. ISBN ISBN ISBN Printed in Ukraine. INFACON XIV SPONSORS PLATINUM SPONSORS: BRONZE SPONSORS: SPONSOR: The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry I PARTNERS: Technical Tours to Nikopol Ferroalloy Plant supported by Nikopol Ferroalloy Plant Pobuzhye Ferronickel Plant supported by Solway Group The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry II The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry III The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry IV TABLE OF CONTENTS Volume I: General aspects Ferroalloy industry of Ukraine: current status, development trends and future prospects Grishchenko S.G., Kutsin V.S., Kravchenko P.A., Soloshenko V.P., Bespalov O.L., Kudryavtsev S.L. 1 History and New milestones in submerged arc furnace technology for ferro alloy and silicon production Fröhling C., Meyn M., Degel R., Niekerk A.van., Köneke M. 7 PRODUCTION TECHNOLOGIES AND OPERATION Presmelting Operations Technology improvement of refractory chromiteores clotting Akberdin A., Kim A., Zinyakova O. 17 The development of fine manganese concentrate lumping technology at PJSC Nikopol Ferroalloy Plant Kutsin V.S.,Olshansky V.I., Filippov I.Yu., Chumakov А.А. 22 Resource saving in manganese ferroalloy production using low-grade manganese ore concentrates Рrojdak Y. S., Myanovskaya Y. V. 27 Charge and briquettes properties for the production of aluminum-silicon alloys Ovcharuk A.N., Taran A.,Krivenko V.V., Mingsheng Y. 32 Chromium Alloys Production and Operation Study of carbothermic reduction processes in the manufacture of high-carbon ferrochrome Zayakin O.V., Zhuchkov V.I., Afanasyev V.I. 39 Vacuum-thermal method of deep refining of ferrochromium in solid state Gasik M. I., Gasik M. M. 44 Implementation of Tenova pre-heating technology at JSC Kazchrome Jonker A.P., Broadbent M. 48 High carbon ferrochromium operational manageability while diversifying products Yavuzhan K. 52 Evaluation on heat and materials balance of CO involved in converter process for M-LcFeCr production 2 Yu H. C., Wang H. J., XU Z. B. 58 Manganese Alloys Production and Operation Mastering of ferrosilicon manganese melting with highly reactive reducing agent Grishchenko S.G., Ovcharuk A.N., Olshansky V.I., Filippov I, Yu., Taran A.Yu., Chalenko V.I., Dudyak V.N., Pavlenko S.V. 65 Manganese ferroalloys production from Russian manganese ores Dashevskiy V.Ya., Zhdanov A.V., Zhuchkov V.I., Leontyev L.I. 73 The use of fine water sprays to suppress fume when casting refined ferromanganese Cowx P., Nordhagen R., Kadkhodabeigi M., Els L., Kero I. 81 The AlloyStreamTM process for HCFeMn production Muller J., Coetsee T., Groenewald J.A., Toit de A.A. and Zeelie D. 91 The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry V Pretreatment unit in ferromanganese production Tangstad M., Ichihara K., Ringdalen E. 99 The determination of rational technological parameters of ferrosilicon manganese melting based on the process electrical characteristics Kutsin V.S., Gladkikh V.A., Olshansky V.I.,. Filippov I.Yu., Kyzmenko S.N,. Mikhalyov A.I,. Ruban A.V 107 Ferronickel, Ferrosilicon and other ferroalloys Production and Operation Study on slag resistance of refractories in submerged arc furnaces melting ferronickel Dong Hu, Pei Xiao Liu, Shao Jun Chu 115 Innovative electric smelter solutions of the SMS Group for the silicon industry Degel R., Fröhling C., Kalisch M., Hecker E., Oterdoom H. 122 Production of molybdenum-, nickel-, chromium-containing iron-based alloys via metallothermic process Gungor M.N., Benzesik K., Bugdayci M., Yucel O. 133 Ferromolybdenum production according to silicoaluminthermal method: high quality, chemical and granulometric composition stability Kornievskiy V. N., Panchenko A. I., Logozinskiy I. N., Salnikov A. S., Gasik M. I., Shibeko P. A., Budnik I. L., Yakovitskiy A. V. 139 Search for a new compositions of boron-containing ferroalloys, their application and development of appropriate production techniques Zhuchkov V.I., Sychev A.V., Babenko A.A., Akberdin A.A., Kim A.S. 145 A step change in calcium carbide production technology McCaffrey M., Robinson S., Sizemore F., Kangmin X., Shiyun Z., Xiaojing Z., Shicheng L., Xiaowen J., Dengping Z. 149 A 90 MW calcium carbide furnace – process and electrical scale-up McCaffrey M., Kadar L., Dong J., Wasmund B., Robinson S., Wharton D. 158 Post Taphole Operations Slag atomising technology: unlocking real value Mostaghel S., Cramer M., Faucher S., So L., Lee S.K., Oh S.-Y. 166 Towards computational modelling of multiphase flow in and around furnace tap-holes due to lancing with oxygen: an initial computational and cold-model validation study Erwee M.W., Reynolds Q.G., Zietsman J.H., Cromarty R.D., Lexmond A.S. 174 Sensor-based technology for ore and slag sorting Gryshan D. and Kulish A. 184 Laboratory study of slag metal separation for HC FeMn Ringdalen E., Solheim I., Tang K., Eidem P-A., Ravary B. 190 ENGINEERING ASPECTS AND CONCEPTS Furnace Design and Equipment Ilmenite Smelting in a Pilot Scale DC Furnace Pisilä S., Palovaara P., Jong de A., Aula M. 202 ESS smelting technology enabling FeNi smelting from limonite Erasmus L., Fourie L.J. 210 The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry VI Rapid redesign and Restart of the Vale Onça Puma Nickel Smelter Southall S., Zemanek A., Griebeler A., Stevens G., Emery B., Damasceno R. 219 Construction and commissioning of ERAMET SiMn + EMM plant in Gabon L’Huillier P. 229 Intelligent solutions for ferroalloy production of Paul Wurth Kappes H., Gantenberg M., Degel R., Kinzel K-P., Hoffmann M., Krüssmann M., Flammang M., Degel R. 238 A 90 MW calcium carbide furnace – mechanical design McCaffrey M., Ku H., Reid R., Robinson S., Sizemore F. 247 Lining Refining of ferroalloys with the CLU® process Beskow K., Rick C-J and Vesterberg P. 256 RHI refractory solutions - a reliable partner for the ferroalloys industry Wenzl C., Spanring A. 264 Lining management - residual life assessment Mohanty B. 270 Evaluation of furnace refractory linings after sixteen years of producing silicomanganese O’Shaughnessy P. and Roux Le F. 278 Burn down, excavation and relining ENS12 2013/2014 Lindseth A.G., Xayasenh A., Lecacheux B., Cowx P., Dimet A. 300 Advances in waterless cooling for extended refractory campaign life Parravani M., Jastrzebski M., Coull Z., Wasmund B. 308 Monitoring of electrical, thermal and technological processes in ore-thermal electric furnace for the production of high-carbon ferrochrome Kolyvanov S.Y., Savel'ev S., Rubtsovclaim V.V., Kondrashov, V. P., Lykov, A. G. 317 Design and Control Temperature profiles in Søderberg electrodes Skjeldestad A., Tangstad M., Lindstad L., Larsen B. 327 Electrode voltage measurement in electric furnaces: analysis of error in measurement and calculation Tracy P., Gerritsen T., Saber F. 338 Electrode controller-leading to energy efficiency Mohanty B. 349 Research of the operation modes of self-baking electrodes of high-power electric ore-smelting furnaces at PJSC “Nikopol FerroAlloy Plant” Grinshpunt A.G., Dedov Yu.B. 358 The Fourteenth International Ferroalloys Congress May 31-June 4, 2015 Energy efficiency and environmental friendliness Kiev, Ukraine are the future of the global Ferroalloy industry VII