Production of molybdenum-, nickel-, chromium-containing iron-based alloys via metallothermic process

The main usage area of chromium in metallurgy is ferrochromium, and FeCr covers 95% of the total chromium production. 90% of this ferrochromium is used as an alloying addition in stainless and heat-resistant steels. Although Turkey does not have large reserves of chromite, these ores are preferred to be used in metallurgical sector due to the fact that they have high quality. This study was aimed at producing molybdenum-, nickel-, chromium-containing iron-based alloys via metallothermic process. In Turkey, Eti Krom A.Ş. produces high carbon ferrochromium by consuming 2700 kWh/t energy. In the case of the low carbon ferrochromium production in Antalya, the energy consumption can increase up to 8200 kWh/t. Instead of the electrical energy, aluminum scrap and powder are used for reduction and smelting of low carbon FeCr as the concept of the energy efficiency. Thus, energy consumption and pollution is decreased. In our first experimental set, low carbon FeCr was produced which contains 66%Cr and 0.2% C. Additionally, low carbon iron-based alloys were also produced by metallothermic process. In the second set of the study, millscale was used as iron source. MoO3, Cr2O3, NiO were used as alloying elements. Mg, Si and Al were used as reductants. Millscale is a layer of iron oxide which forms on ferrous materials cooling after being processed in hot rolling or continuous casting plants. Millscale contains iron, iron I, iron II and iron III oxides which results in a 70% total iron content in oxide form. In the millscale studies, Mo 76%, Ni 91%, Cr 62.5% are recovered with these recovery rates, respectively. The samples were characterized by using chemical analysis, AAS, XRD, XRF techniques.