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Ferroalloy

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FERROSILICON

Ferrosilicon Ferroalloy in steel mills and casting as the source of silicon is used. Also in plain carbon steel, low alloy and high-alloy deoxygenation to use in the production of Ferro Alloys silico method of thermite is used.
Silicon role of alloying element in steel production in nuclear electrical transformers and electro is used.
Ferrosilicon as a supplier of silicon to gray and ductile iron casting rate of 3% is used.
The material forming the base Ferrosilicon analysis ferrosilico cast magnesium and modifiers.
As part of the wire coating composition (flower pots) in some welding electrodes used.

Ferroalloy Physical properties

melting pointBulk densitySpecial Weight
1240 – 13501.63.2

Grading (mm)

(10 – 100)(60 – 80)(10 – 60)(3 – 10)(0 – 3)

Major applications

  • Operating deoxidizer in steel
  • That increase in the production of steel and iron alloy of silicon high silica
  • Factors modifiers in graphite cast iron (spherical knotted sheets)
  • The magnesium ferrosilicon alloys for the production of ferro manganese and silicon
  • For the production of graphite electrodes used in welding

packing

  • 1 MT Big Bag
  • Bulk in container
  • FeSi (0-3)mm in 10kg bags

HIGH PURITY ERROSILICON

Ferrosilicon 75% HP (High Purity) is an alloy which is produced by combining around 75% 75% of Silicon and 25% of iron. This product is manufactured from selected raw material with high purity degree and rigorous quality control, which guarantees wide homogeneity among lots.
This grade is used in the production of grain-oriented electrical steel as well as steels requiring low level of Aluminum, Carbon, Calcium, titanium, boron and other residual elements. This product is used in grades of steel where high purity, low residual input are required. Destined to the production of electric transformer scores, power generators and other electric equipment.

MICROSILICA

The American Concrete Institute (ACI) defines Microsilica as “very fine non-crystalline silica produced in electric arc furnaces as a by-product of production of elemental silicon or alloys containing silicon” (ACI 116R). It is different from pulverized silica. Microsilica, also known as silica fume.
Standard Specification
IFI Microsilica (Silica Fume) meeting the requirements of ASTM C 1240, EN 13263, JIS A 6207 and ISIRI 13278.
Main Applications
•  Concrete and cements
•  Refractory and Ceramics
•  Polymer and chemical industry
•  Oil well grouting

Microsilica Applications in Concrete
The 65 percent of global microsilica production used for concrete and cement. The applications include:
• Blended cements
• High Strength Concrete (HSC)
• High Performance Concrete (HPC)
• Self-Consolidating Concrete (SCC)
• Shotcrete
• Ultra-low permeability concrete
• Cementitous repair products
• Additive agent for carbon fiber composites

Dosage
IFI Microsilica is recommended at an addition dosage of 7 to 15% by mass of cement.

Advantages of Using Silica Fume
• High early compressive strength
• Very low permeability to chloride and water intrusion
• Enhanced durability
• Increased modulus of elasticity
• High tensile flexural strength
• Increased toughness
• High cohesiveness and low return materials
• Superior resistance to alkali–silica reaction (ASR)
• Low bleeding
• Increased abrasion resistance on decks, floors, overlays and Spillway
• Decreased risk of concrete surface dusting
• Superior resistance to chemical attack from chlorides, acids, and sulfates

Benefits
• Reduce life cycle cost
• Reduce construction costs by designing slender elements
• Reduce bridge construction costs by increasing span
• Reduce shotcrete costs by decreasing return materials
• Reduce paving costs by one pass finishing
• Reduce corrosion protection costs

Environment Issue
Microsilica is a byproduct of the factory and thereby does not have cement problems.

Examples
• Milad Tower
• Bandar Abbas Desalination Plant
• Asaluyeh Water Tank
• Ahvaz Subway Infrastructure
• Qom Monorail

Chemical Composition

SiO2Al2O3Fe2O3ClCNa2OK2OMgOSCaOPLOIpH
90 -950.6-1.21.2-1.80.04-0.070.8-2.00.3-0.60.4-0.80.6-1.20.04-0.080.5-1.00.04-0.061.5-2.58.0-9.5

Physical Properties

Bulk density (as-produced), kg/m3Specific gravityPhysical stateParticle size (typical)ColorSpecific surface m2/g
310 – 3502.2amorphous< 1 µmLight gray15 – 30

Packaging
• Big Bag (750 kg)
• Medium Bag (500 kg)
• Small bag (40 kg)

Export Destination
• India
• Pakistan
• Iraq
• Turkey
• Tajikistan
• UAE
• Oman
• Qatar

Storage
Microsilica stores similar to cement, except the silo used for microsilica be equipped with a rubber fill hose rather than a steel pipe. If the material gets wet there will not be a hydration reaction. However, the microsilica agglomerates may become more difficult to disperse when assed to concrete. Ensure that the mixing is adequate to break up the particle agglomerations. Otherwise, it will serve as filler material.

Batching and Mixing
Never place microsilica in any form into an empty mixer before any other ingredients. Do not load more than 63% of rated capacity of drum.

Adding Admixture
It is necessary to use microsilica in combination with a water-reducing admixture or a superplasticizer. The required amount of AEA will usually be 150 to 200% of dosage without microsilica.

Bleeding
Bleeding microsilica concrete is zero or very low. The lack of bleeding means that finishing can start earlier and be completed sooner. The potential of plastic shrinkage cracking in microsilica concrete is higher than normal concrete. Proper curing can reduce plastic shrinkage cracking.

Placing and Curing
Microsilica concrete has been successfully placed by all means of placing normal concrete. Curing be started 10 to 15 minutes after the concrete placed.

Health Issues
•  CAS Number: 69012-64-2
•  Incompatible materials: Hydrofluoric acid (HF)
•  Use safe work practices to avoid eye or skin contact and inhalation.
•  Heating the product above 1000 C can result in the formation of crystalline SiO2-modifications as cristobalite / tridymite which may cause pulmonary fibrosis (silicosis).

Chemical & Physical Properties of Silica Fume Produced by Iran Ferroalloy Industries Co. Compared to Different Standards

Chemical & Physical CompositionASTM C 1240 – 2015EN 13263 – 2005JIS A 6207 – 2016Iran Ferroalloy Industries Silica Fume 2009 – 2017
SiO2 (%)Min. 85%Min. 85Min. 8590 – 95
Al2O3 (%)_Max. 1.5Max. 1.50.6 – 1.2
Fe2O3 (%)_Max. 2Max. 21.2 – 1.8
CaO (%)_Max. 1Max. 10.5 – 1.0
MgO (%)__Max. 50.6 – 1.2
Na2+0.658k2O (%)_Max. 2Max. 20.7 – 0.9
C (%)___0.8 – 2.0
Cl (%)_Max. 0.3Max. 0.10.05 – 0.07
pH__4 – 8.58
Moisture Content (%)Max. 3__Max. 1.5
Loss on Ignition (LOI) (%)Max. 6Max. 4Max. 51.5 – 2.5
Special Surface (m2/gr) (%)Min. 1515 -35Min. 1515 – 30
Bulk Density (Kg/m3) (%)___310 – 350

FERROSILICON OFF GRADE

Ferrosilicon off grade is a by-product when making Ferrosilicon. The silicon content is from 55% to 65%, and the rest are Al ,C, S, P, Ca etc.

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