KMB - GASFERROSIL - Use of Natural Gas in Ferroalloy and Si production and Ilmenite processing

Use of natural gas in production of Titania slag, Silicon and Ferroalloys is a part of the industry's long-term innovation work regarding new and sustainable processes. Substitution of coke or coal by natural gas reduces the CO2 emissions in the productio n itself, and it also reduces the disadvantages associated with coke production. Additionally, the silicon and manganese ferroalloys may be produced at lower temperatures, reducing overall energy consumption. Production of ferroalloys and Si using solid c arbon materials is well understood, but not much work is done where natural gas is used as reductant. A couple of issues pertaining to these processes should not be forgotten when trying to meet the challenges addressed here: 1.The end reduction, e. g. th e reduction of MnO to metallic Mn, must be done by carbon, or fixed C as it is often called, and the by-product is then CO gas:The amount of carbon needed for the end reduction stage is constant or "incompressible". The main consequence of this fact here is that it is only the C in the Natural Gas that can be utilised for this purpose. 2.Although the main processes equipment used in this industry, the electric furnaces, look very similar and products are often utilized by the same end users, the actual pr ocesses and their operation are very different. The GASFERROSIL partners find it necessary to assess the presently known thermodynamic possibilities and limitations as well as kinetic parameters from prevailing literature in light of the proposed resear ch tasks. A technical feasibility study will be performed during the first phase of GASFERROSIL, and will form a basis for further innovation and development of new or adapted production processes facilitating the utilisation of Natural Gas in this indust ry. The project aims at determining where, how, and under what limitations, conditions and changes relative to present state can this industry utilize Natural Gas.