This study investigates the production of high-carbon ferrochrome (HCFeCr) using pre-reduced chromite pellets. Chromite ore from the Kempirsai deposit, semicoke as a reducing agent, and activated bentonite as a binder were used for pellet preparation. Pellets with a size of 12–14 mm were produced and subjected to reduction roasting at 1400 °C for 1–3 h. The results showed that increasing the roasting time promoted chromite reduction and increased the chromium metallization degree. After 3 h of roasting, the chromium metallization degree reached 43.93%. SEM analysis confirmed the formation of metallized chromium-containing phases and a porous structure favorable for subsequent smelting. Smelting experiments were carried out in a 0.1 MVA ore-thermal furnace using pre-reduced pellets. Stable furnace operation, satisfactory slag fluidity, and effective separation of metal and slag were observed. The obtained high-carbon ferrochrome contained 68.92 wt.% Cr, 1.54 wt.% Si, and 7.11 wt.% C. Chromium recovery into the alloy reached 92.17%, while the slag contained 2.14 wt.% Cr₂O₃. The specific electric energy consumption during experimental smelting was 4648.1 kWh/t of ferrochrome. Recalculation to industrial conditions showed an expected energy consumption of 3132.76 kWh/t, confirming the potential of pre-reduced chromite pellets for energy-efficient ferrochrome production.

The present study compares the effects of temperature, holding time, and nominal carbon excess on the pre-reduction of Donskoy chromite pellets with semi-coke. FactSage equilibrium calculations were interpreted alongside three laboratory series with different baselines. At 180 min with activated bentonite and 25% carbon excess, chromium metallization increased from 58.5% at 1350 °C to 87.0% at 1500 °C. At 1400 °C with attapulgite and 10% excess, extending holding time from 195 to 210 min increased chromium metallization from 70.6% to 82.8%, while residual carbon decreased from 4.96 to 4.00 wt.%. At 1500 °C and 180 min with activated bentonite, increasing excess from 15% to 25% increased chromium metallization from 68.9% to 87.0% and residual carbon from 2.30 to 4.74 wt.%. These condition-specific endpoints do not establish factor interactions, an optimum regime, or a kinetic mechanism. Unavailable uncertainty estimates limit quantitative interpretation. Equilibrium predictions and elemental maps do not independently verify the experimental phase sequence. Any industrial benefits, including chromium recovery, energy consumption, and continuous-process performance, require further validation.