The article provides a brief overview of technologies and methods for processing dispersed metallic waste generated during ferroalloy production, including high-carbon ferrochrome (HCFeCr). It is noted that the most cost-effective and rational method for reusing metallic dust is briquetting. Considering the development of briquetting technologies, as well as the latest equipment and binder materials involved in this process, aspiration dust from ferrochrome crushing can be fully utilized in metallurgical recycling. To verify this assumption, laboratory studies were conducted using polymer-based binders and liquid glass as a baseline option. The methodology of briquetting using both laboratory and industrial presses is described, along with an assessment of the mechanical properties of the briquettes. The studies indicate that the introduction of an inert filler (gas-cleaning dust) into the metallic dust composition improves the briquetting ability of the mixture by enhancing adhesion between metal particles and the binder. The obtained industrial briquette samples exhibit high mechanical strength, ensuring their further use in metallurgical processing. The study concludes that semi-dry briquetting using hydraulic vibropresses is a promising approach for the utilization of dispersed ferroalloy waste.

This study presents the results of laboratory experiments on the processing of lateritic nickel ores mixed with coal and CaO, followed by the use of the obtained product for the smelting of nickel-containing ferroalloy by the metallothermic method. The study analyzed the thermodynamic effects of complex reductant concentration (silicon- and aluminum-containing alloy) on the reduction degree of nickel and iron. An experimental process resulted in a product containing Ni_total (2.60%) and Fe_total (60.52%), obtained through reduction roasting of lateritic nickel ore mixed with coal and an addition of 20 g of CaO at a temperature of 1150 °C. Under laboratory conditions, a nickel-containing ferroalloy was successfully obtained using the product after reduction roasting and a complex alloy as the reducing agent. The following optimal process parameters were determined: reductant consumption of 20 g per 100 g of the reduction roasting product, smelting temperature of 1600 °C, and slag basicity (CaO/SiO₂) of 0.5. In this case, a nickel-containing ferroalloy with 72% iron, 15% nickel, and up to 5% chromium was successfully obtained through silicon and aluminum reduction using a complex alloy. A microstructural analysis of the nickel-containing alloy was conducted using an electron probe microanalyzer (JXA-8230) in combination with scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS). The results showed that silicon and iron were the dominant elements in all particles. Nickel was detected at concentrations of up to 15.02 wt. %, while chromium reached 3.47 wt. %. Depending on the silicon concentration, the nickel-containing ferroalloy is recommended for corrosion-resistant steel production (Si < 5%) and as a reducing agent for ferronickel production (Si > 5%).

This article presents the results of laboratory studies on the smelting of nickel–chromium-containing ferroalloys from low-grade nickel ores from Kazakhstan. X-ray phase analysis was performed on raw materials, which included quartz, nontronite, chromium metahydroxide, goethite, magnetite, iron chromite, and nickel (II) silicate. The reduction reactions of metal oxides with carbon and carbon monoxide were studied as the temperature increased. Experimental smelting was carried out in a Tammann furnace at 1500–1550 °C using three types of reducing agent: RK coke, as well as its mixtures with low-ash Shubarkol coal, in ratios of 75:25 and 50:50. The second option demonstrated the highest economic efficiency, achieving a 91% nickel recovery rate, reduced coke consumption, and a slag-to-metal ratio of 3.07. Chemical analysis showed that the nickel content in the obtained alloys ranged from 2.5% to 6.5%, while chromium content ranged from 2.6% to 4.5%. X-ray phase analysis confirmed the presence of Fe₂Ni_0.6Si, Fe₅Si₃, and Fe₂CrSi phases in the alloy structure. Local element concentrations varied within the following ranges: Fe—55–59%, Ni—2–10%, Cr—2–7%, and Si—29–35%. The results of this study confirmed the feasibility of producing a nickel–chromium-containing alloy with a nickel content of 2–10% and a chromium content of 2–7%.

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.

This study investigates the effectiveness of various beneficiation methods for recovering chromium from refined ferrochrome slag. Dry magnetic separation at different field intensities (0.45 T and 0.8 T) showed that selective extraction of metallic chromium (Cr_met) is more efficient at 0.45 T, achieving a recovery rate of up to 90.05%. Pneumatic separation using SEPAIR technology demonstrated promising results, especially for wide particle size fractions (0–20 mm), where chromium recovery reached 40.32% due to density differences between slag particles and metallic inclusions. Enrichment on a shaking table proved to be the most selective method, producing a concentrate with 29.9% Cr and 90.7% recovery, although the yield was low (3.8%). SEM-EDX and SEM-BSE analyses confirmed the heterogeneous phase composition of slag grains, revealing chromium–iron alloys embedded in oxide matrices. Based on laboratory experiments and material characterization, it is concluded that magnetic separation can be used for preliminary concentration, pneumatic classification is effective for processing bulk slag with economic potential, and gravity concentration on shaking tables is suitable for producing high-grade concentrates. The resulting tailings, low in chromium, are suitable for reuse in the production of building materials after carbonation treatment.

This study addresses the problem of efficient utilization of aspiration dust (AD) generated during crushing of high-carbon ferrochrome (HCFeCr). To solve this issue, a briquetting technology was proposed, involving aspiration dust blended with dry gas-cleaning dust (20 wt.% as filler) and an organic polymer binder (3 wt.%). The produced briquettes demonstrated high mechanical strength (average 195 kg per briquette in splitting strength and 98% drop resistance), ensuring maximum integrity during transportation and handling. Pilot-industrial remelting of 35 tons of briquettes in a 1.8 MVA direct current electric arc furnace (DC EAF) confirmed the effectiveness of the proposed technology for HCFeCr production. Chromium recovery into the alloy reached 94%, which is 3–4% higher compared to remelting of loose dust. The specific electric energy consumption was 1600 kWh/t, representing a 29% reduction compared to loose dust processing. The produced metal met commercial grades FeCr800–FeCr900 specifications. Additional advantages included elimination of dust formation, reduction in fines generation during crushing of the final metal to 15%, and improved environmental performance. The developed technology represents an economically and environmentally viable solution for comprehensive recycling of ferroalloy dust waste.