Thermodynamic Assessment and Process Development for Smelting Aluminosilicochrome from Technogenic Wastes of Ferroalloy and Coal Production

Aristotel Zeinullinovich Issagulov, Aibar Myrzagaliyev, Saule Sagintayeva, Yerbolat Makhambetov

Metals, 2026

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DOI 10.3390/met16060613
Data confidence 70 medium
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Abstract

This study evaluated the production of aluminosilicochrome alloy (ASC) from technogenic wastes generated by ferroalloy and coal production. Chromite spinel dust from high-carbon ferrochrome gas cleaning, microsilica from ferrosilicon gas cleaning, and coal sludge as a reductant were used as raw materials. Thermodynamic modeling of the Fe–Cr–Si–Al–C–O system in HSC Chemistry 10 predicted that ASC formation is most favorable at 2000–2200 °C, where the metallic phase should contain (wt. %) 28.27–29.46 Cr, 35.21–36.06 Si, 10.14–11.89 Al, and 10.21–10.45 Fe. These predictions were tested by smelting a pre-agglomerated monocharge in a 100 kVA single-electrode electric arc furnace. The resulting alloy contained (wt. %) 24.23 Fe, 32.03 Si, 22.32 Cr, 18.70 Al, 0.36 C, 0.028 P, and 0.015 S. The experiments confirmed the formation of Si-, Cr-, and Al-rich ASC and demonstrated the feasibility of carbothermic production from these wastes. SEM-EDS revealed a multicomponent metallic matrix with pronounced microstructural heterogeneity and local redistribution of Fe, Si, Cr, and Al. Overall, the results support the use of fine technogenic wastes for producing a complex Fe–Cr–Si–Al alloy.