In Si and FeSi production, the main Si source is SiO₂, in the form of quartz. Reactions with SiO₂ generate SiO gas that further reacts with SiC to Si. During heating, quartz will transform to other SiO₂ modifications with cristobalite as the stable high-temperature phase. Transformation to cristobalite is a slow process. Its rate has been investigated for several industrial quartz sources and has been shown to vary considerably among the different quartz types. Other differences in behavior during heating between these quartz sources, such as softening temperature and volume expansion, have also been studied. The quartz-cristobalite ratio will affect the rate of reactions involving SiO₂. The industrial consequences and other implications of the observed difference between quartz types are discussed. Initial studies of industrial quartz were published by Ringdalen et al. In the current work, a new experimental method has been developed, and an investigation of several new quartz sources has confirmed the earlier observed large variation between different sources. The repeatability of the data has been studied and the effect of gas atmosphere investigated. The results from the earlier work are included as a basis for the discussion.

Ferrochrome (FeCr) is the main source of virgin chromium (Cr) units used in modern-day chromium (Cr) containing alloys. The vast majority of produced Cr is used during the production of stainless steel, which owes its corrosion resistance mainly to the presence of Cr. In turn, stainless steel is mainly produced from Cr-containing scrap metal and FeCr, which is a relatively crude alloy between iron (Fe) and Cr. The production of FeCr is an energy and material-intensive process, and a relatively wide variety of by-products, typically classified as waste materials by the FeCr industry, are created during FeCr production. The type and extent of waste generation are dictated by the smelting route used and the management practices thereof employed by a specific smelter. In some cases, waste management of hazardous and non-hazardous materials may be classified as insufficient. Hazardous materials, such as hexavalent Cr, i.e., Cr(VI), -containing wastes, are only partially mitigated. Additionally, energy-containing wastes, such as carbon monoxide (CO)-rich off-gas, are typically discarded, and energy-invested materials, such as fine oxidative sintered chromite, are either stockpiled or sold as ordinary chromite. In cases where low-value containing wastes are generated, such as rejects from ore beneficiation processes, consistent and efficient processes are either difficult to employ or the return on investment of such processes is not economically viable. More so, the development of less carbon (C)-intensive (e.g., partial replacement of C reductants) and low-temperature pellet curing processes are currently not considered by the South African FeCr smelting industry. The reasoning for this is mainly due to increased operation costs (if improved waste management were to be implemented/higher cost reductants were used) and a lack of research initiatives. These reasons result in the stagnation of technologies. From an environmental point of view, smelting industries are pressured to reduce C emissions. An attractive approach for removing oxygen from the target metal oxides, and the mitigation of gaseous C, is by using hydrogen as a reductant. By doing so, water vapor is the only by-product. It is however expected that stable metal oxides, such as the Cr-oxide present in chromite, will be significantly more resistive to gaseous hydrogen-based reduction when compared to Fe-oxides. In this review, the various processes currently used by the South African FeCr industry are summarized in detail, and the waste materials per process step are identified. The limitations of current waste management regimes and possible alternative routes are discussed where applicable. Various management regimes are identified that could be improved, i.e., by utilizing the energy associated with CO-rich off-gas combustion, employing a low-temperature alternative chromite pelletization process, and considering the potential of hydrogen as a chromite reductant. These identified regimes are discussed in further detail, and alterative processes/approaches to waste management are proposed.

The chromium (Cr) content of stainless steel originates from recycled scrap and/or ferrochrome (FeCr), which is mainly produced by the carbothermic reduction of chromite ore. Ever-increasing pressure on FeCr producers to curtail carbon emissions justifies migration from traditional FeCr production routes. The interaction between hydrogen and chromite only yields water, foregoing the generation of significant volumes of CO-rich off-gas during traditional smelting procedures. For this reason, the use of hydrogen as a chromite reductant is proposed. In addition to thermodynamic modelling, the influence of temperature, time, and particle size on the reduction of chromite by hydrogen was investigated. It was determined that, at the explored reduction parameters, the iron (Fe)-oxides presented in chromite could be metalized and subsequently removed by hot-acid leaching. The Cr-oxide constituency of chromite did not undergo appreciable metalization. However, the removal of Fe from the chromite spinel allowed the formation of eskolaite with the composition of (Cr_1.4Al_0.6)O₃ in the form of an exsolved phase, which may adversely affect the reducibility of chromite. The study includes the limitations of incorporating hydrogen as a reductant into existing FeCr production infrastructure and proposes possible approaches and considerations.

The majority of ferrochrome (FeCr) is produced through the carbothermic reduction of chromite ore. In recent years, FeCr producers have been pressured to curve carbon emissions, necessitating the exploration of alternative smelting methods. The use of hydrogen as a chromite reductant only yields water as a by-product, preventing the formation of carbon monoxide (CO)-rich off-gas. It is however understood that only the Fe-oxide constituency of chromite can be metalized by hydrogen, whereas the chromium (Cr)-oxide constituency requires significantly higher temperatures to be metalized. Considering the alternation of chromite’s spinel structure when oxidized before traditional smelting procedures, the effects on its reducibility using hydrogen were investigated. Firstly, the effect of hydrogen availability was considered and shown to have a significant effect on Fe metallization. Subsequently, spinel alternation induced by pre-oxidation promoted the hydrogen-based reducibly of the Fe-oxide constituency, and up to 88.4% of the Fe-oxide constituency was metallized. The Cr-oxide constituency showed little to no reduction. The increase in Fe-oxide reducibility was ascribed to the formation of an exsolved Fe₂O₃-enriched sesquioxide phase, which was more susceptible to reduction when compared to Fe-oxides present in the chromite spinel. The extent of Fe metallization of the pre-oxidized chromite was comparable to that of unoxidized chromite under significantly milder reduction conditions.

Process simulation was integrated with life cycle assessment to evaluate process efficiency and environmental impact of the production of manganese ferroalloys for various production modes and different ore mineralogies. Utilizing HSC Sim, the model was designed to evaluate the production process with or without a pretreatment step, where results for simulated cases using a four-zone ferromanganese furnace model were exported to openLCA for a complete life cycle assessment. Two main production scenarios were simulated: a closed ferromanganese furnace running on the duplex method and an open furnace running on the discard slag approach. The closed furnace scenario achieved a 17.5% reduction in energy consumption and a 16.2% decrease in direct CO₂ emissions with CO-rich off-gas pretreatment. The open furnace scenario showed an 11.2% reduction in energy consumption with thermal solar energy pretreatment but no change in CO₂ emissions.

Very little research on Søderberg electrodes has been published in the journal peer reviewed public domain. The main aim of this work is to characterise a Søderberg electrode that was cut off approximately 0.5 m below the contacts shoes of a submerged arc furnace. Additionally, the characterisation data can be used to verify if Søderberg electrode models accurately predict important electrode characteristics. The operational history (slipping, current, and paste levels) proved that the case study electrode was a representative specimen. The characterisation results indicated no significant electrical resistivity, degree of graphitisation (DOG), and bulk density changes from 0.7 to 2.7 m on the non-delta side (outward facing), while these characteristics changed relatively significantly on the delta side (inward facing) of the electrode. The area where the submerged arc would mostly like jump off the electrode had the lowest resistivity, as well as highest DOG and bulk density. No significant difference in porosity as a function of length below the contact shoes were observed; however, slight increases occurred near the perimeters. It was postulated that oxidation of carbon resulted in increased pore volumes near the electrode perimeter. No significant difference in compressive breaking strength was observed over the electrode area investigated.