Kutsin V. A theoretical synthesis, research and development of resource-saving technologies and processes for production of manganese ferro-alloys in high-power electric furnaces

The thesis is devoted to theoretical generalization, research, development and introduction of innovative technologies and resource efficient processes for production of manganese sinter and melt at high power electric ferrosilicomanganese. Developed a thermal model of sinter charge ignition, which is adapted to the production of manganese sinter. Theoretically justified and resolved the problem of ferroalloy gas instead of natural gas and hard coal instead of coke. For the first time using databases FToxid, FACT and FACT 5,3 and the software package "FactSAGE 6,0" used to study the thermodynamic and computer simulation of phase equilibria of the system MgO-MnO-SiO2-5% CaO, which describes the manganese-magnesia sinter. First constructed the liquidus surface of this system. Scientifically justified and development the technology of production of manganese-magnesia sinter with a ferronickel slag. With the involvement of the software package "FactSAGE 6,0" was first performed computer simulations of the thermodynamic carbon reduction processes for production of ferrosilicomanganese. It is shown that an increase in MgO in the furnace slag enhances the extraction of manganese in the alloy. Developed and introduced in the six electrode 63 MVA electric furnace innovative effective technology for smelting ferrosilicomanganese using manganese-magnesia sinter. Reduced unit costs for 1 ton of ferrosilicomanganese was: manganese materials - 39 kg; coke - 12 kg; quartzite - 39 kg; electrical energy - 64 kW per hour. For the first time developed a control algorithm for high-electric mode (63...75 MVA) of electric furnaces for smelting manganese ferroalloys in the zone tariff of electricity. Explored, developed and implemented new technology moldboard separation of slag-removing with obtaining metal-slag mixture (35% Mn) and its use in the underlying technology of manganese ferroalloys. Designed, researched and introduced the technology of briquetting non-conforming fraction of ferrosilicomanganese. Designed the technology of production of crystalline glass-reinforced materials from ferrosilicomanganese liquid slag and production of containers for storage and disposal of radioactive waste. For the first time mathematical simulation of the spread of dust and gas emissions from stationary sources sinter plant and the production of manganese ferroalloys plant. The introduction of the thesis developed in the science-based technologies and processes in the production of manganese sinter and ferrosilicomanganese provided significant economic benefits 464 820 thous. (for 2011).