Fine classes of metal dust generated during the production of ferroalloys increase the likelihood of irretrievable losses, creating the prerequisites for the development of rational methods for processing this material. One of the known technologies for recycling dispersed raw materials in metallurgical processing is their direct remelting. Although this technology is easily feasible, it has several significant drawbacks, among which the main problem remains the high dust carryover of fine material by ascending gas-thermal flows. A potential solution could be the preliminary preparation of raw materials through agglomeration. Domestic enterprises producing various types of ferroalloys have the necessary infrastructure and equipment for agglomerating dispersed ore materials, but the lack of experience and resource-saving technologies for processing metal dust prevents their full integration into metallurgical processing. In this regard, there is significant interest and demand from ferroalloy enterprises for the development of new methods to involve dispersed metal production waste in secondary recycling, adapted to existing agglomeration equipment. Numerous studies have shown that the cheapest method of agglomeration is briquetting. Given the advancement of briquetting technologies, as well as the use of the latest equipment and binding materials in this process, it can be assumed that this will allow for more complete integration of aspiration dust from ferrochrome crushing into metallurgical processing. To test this assumption, studies were conducted on the physicochemical properties of aspiration dust from ferrochrome crushing, assessing the possibility of obtaining an agglomerated product with the required strength parameters. The results of these studies demonstrated the fundamental possibility of producing high-carbon ferrochrome from briquetted material made from aspiration dust of ferrochrome crushing.

The research presented in the article is devoted to the study of the influence of phase compounds on the friability of the Fe-Si-Mn-Al complex alloy. The urgency of the problem lies in the development of technology for producing a non-scatterable alloy from manganese-containing ores and high-ash coals. The main goal of the work is to determine the range of alloy compositions and the resulting phases that affect the dispersibility of the alloy, which is critically important for its industrial implementation. Research methods include thermodynamic diagram analysis (TDA) using data on the standard enthalpy of formation of intermetallic compounds, as well as experimental tests in an ore-thermal electric furnace with a capacity of 200 kV*A. The results show that Fe-Si-Mn-Al complex alloys form a variety of silicide and aluminide phases, including intermetallic compounds and ternary systems, which is critical for understanding and controlling their physicochemical properties. When smelting a complex alloy, the content of leboite (Fe3Si7) in the Fe-Si-Mn-Al system plays a significant role. The development of smelting technology will be aimed at avoiding the FeSi2-Fe3Si7-F2(FeAl3Si2)-Mn11Si19 tetrahedron area. This approach to controlling the composition of a complex alloy is critical to ensuring its consistent friability properties in industrial applications. Thus, this work represents an important step in understanding the physical properties and stability of Fe-Si-Mn-Al complex alloys, which have potential for widespread use in metallurgical and other industrial applications.

The research presented in the article is devoted to the study of the influence of phase compounds on the friability of the Fe-Si-Mn-Al complex alloy. The urgency of the problem lies in the development of technology for producing a non-scatterable alloy from manganese-containing ores and high-ash coals. The main goal of this work is to determine the range of alloy compositions and the resulting phases that affect the dispersibility of the alloy, which is critically important for its industrial implementation. Research methods include thermodynamic diagram analysis (TDA) using data on the standard enthalpy of formation of intermetallic compounds, as well as experimental tests in an ore-thermal electric furnace with a capacity of 200 kV*A. The results show that Fe-Si-Mn-Al complex alloys form a variety of silicide and aluminide phases, including intermetallic compounds and ternary systems, which is critical for understanding and controlling their physicochemical properties. When melting a complex alloy, the content of leboite (Fe₃Si₇) in the Fe-Si-Mn-Al system plays a significant role. The development of melting process technology will be aimed at avoiding the FeSi₂-Fe₃Si₇-F₂(FeAl₃Si₂)-Mn₁₁Si₁₉ tetrahedron area. This approach to controlling the composition of a complex alloy is critical to ensuring its consistent friability properties in industrial applications. Thus, this work represents an important step in understanding the physical properties and stability of Fe-Si-Mn-Al complex alloys, which have potential for widespread use in metallurgical and other industrial applications.

Along with the growth in the production of metallurgical grade silicon and high-silicon ferrous alloys, there is a significant increase in the formation of microsilica, which is an ultra-fine technogenic waste. The direct application of microsilica in ore-thermal furnaces is hindered by low bulk density, poor gas permeability, and high dusting. This paper explores the thermophysical and microstructure properties of briquettes based on microsilica, which includes various types of carbonaceous reducing agents such as semi-coke and coal. For manufacturing, the liquid glass was used as the inorganic binder for the preparation of microsilica briquettes. The best variants were chosen based on strength tests carried out during preliminary studies. In the laboratory tests, the stability of the briquettes at elevated temperatures was evaluated. Samples were heated to 1000–1500 °C and subjected to impact testing. Scanning Electron Microscopy with Energy Dispersive Spectroscopy (SEM/EDS) was used to investigate the microstructure and local elemental distribution. It was revealed that the calcinated briquettes of the microsilica–semi-coke mixture have better thermal stability compared to the samples with coal and withstand the temperature range up to 1500 °C. The microstructure of the briquette from the microsilica-semi-coke mixture is characterized by the formation of a more uniform silicate matrix with the presence of a homogeneously distributed carbonaceous component. Coal-based samples show higher heterogeneity and porosity. Therefore, it can be stated that the selection of carbonaceous reductants is one of the key factors influencing the thermal stability of microsilica briquettes.

The study addresses the need to enhance steel properties through improved deoxidation processes, a critical stage in steel production. Traditional deoxidizers such as ferrosilicon, ferromanganese, and aluminum effectively remove oxygen but often lead to the formation of undesirable non-metallic inclusions, negatively impacting steel's mechanical properties. This research investigates the efficacy of complex Fe-Si-Mn-Al alloys as innovative deoxidizers, offering potential advantages in uniform inclusion distribution and mechanical property optimization. Semi-industrial and synthetic complex alloys were produced using high-ash coal, substandard manganese ores, and other materials, followed by metallographic and SEM analyses of deoxidized steel samples. The results highlight significant variations in microstructure, inclusion morphology, and hardness. Steel treated with complex alloys exhibited enhanced uniformity of inclusions and superior mechanical properties, including bainitic and martensitic structures with higher hardness values (up to 46.50 HRc). Compared to traditional deoxidizers, these alloys reduced the presence of detrimental inclusions like manganese sulfides and enhanced the distribution of oxides and nitrides. While martensitic structures offered high strength, challenges like brittleness were noted. This research underscores the potential of complex alloys to revolutionize steel deoxidation, providing pathways for producing high-strength, durable materials suitable for advanced industrial applications.

Silica–carbon briquettes enable the incorporation of fine-grained silica-bearing materials and carbonaceous reductants into the charge used for ferrosilicon smelting. This study examines the composition of the composite disclosed in Patent of the Republic of Kazakh-stan No. 38264, the results of X-ray diffraction analysis of the briquette, and the chemical composition of ferrosilicon samples sequentially collected during the experimental smelting campaign. According to the patent data, the composite contained 41.41% fixed carbon, while the ash content was 39.38% on a dry basis, and the SiO₂ content in the mineral fraction was 90–92%. The first addition of briquettes was recorded at tapping No. 17. However, the exact timing of the corresponding metal sample collection relative to briquette charging is unknown; therefore, this sample was excluded from the comparison between the two operating periods. In samples Nos. 10–16, the Si content ranged from 74.75 to 76.21 wt.%, whereas in samples Nos. 18–24, it ranged from 75.49 to 76.47 wt.%. The corresponding arithmetic mean values were 75.65 and 75.77 wt.%, respectively. Analysis of the X-ray diffraction pattern of metal sample No. 20 allowed two iron–silicon phases to be tentatively identified. A silicon content of approximately 75 wt.% had already been achieved before the introduction of the briquettes. Owing to the sequential nature of the smelting campaign and the absence of a directly comparable material balance, the independent effect of the briquettes on alloy composition, silicon recovery, or electrical energy consumption cannot be reliably established.