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Chromium Bearing Magnesium Silicate Mineral As Alternative Flux To Hard Lump Chromite Ore

Abstract: ABSTRACT CHROMIUM BEARING MAGNESIUM SILICATE MINERAL AS ALTERNATIVE FLUX TO HARD LUMP CHROMITE ORE IN HIGH CARBON FERROCHROME PRODUCTION The present disclosure relates to a blend for smelting chromite ore burden. The blend includes sintered pellet, friable lump, chromium bearing magnesium silicate mineral, hard lump, quartzite, and coke. In an aspect, the sintered pellet comprising in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: 1 to 3, Cr (total): 30 to 35, Fe (total): 12-15 with Cr/Fe ratio 2.40 to 2.53; the friable lump in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: < 0.5, Cr (total): 32 to 38, Fe (total): 13-15 with Cr/Fe ratio: 2.5 to 2.8; the chromium bearing magnesium silicate mineral, in weight%, MgO: 30 to 36, Al2O3:1 to 3, SiO2:35 to 53, Cr2O3: 1 to 7, CaO: 0.5 to 1, Fe2O3: 2 to 6; the hard lump in weight%, MgO: 17 to 23, Al2O3:7 to 9, SiO2: 20 to 24, CaO: < 0.5, Cr (total): 16 to 24, Fe (total): 7-10 with Cr/Fe ratio: 1.8 to 3.2, quartzite and coke. [TO BE PUBLISHED WITH FIG. 1]

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Patent Information

Application #
Filing Date
19 March 2019
Publication Number
39/2020
Publication Type
INA
Invention Field
METALLURGY
Status
Email
delhi@lsdavar.in
Parent Application
Patent Number
Legal Status
Grant Date
2023-12-07
Renewal Date

Applicants

TATA STEEL LIMITED
Bistupur, Jamshedpur, Jharkhand-831001, India.

Inventors

1. NILAMADHABA SAHU
Tata Steel Ltd., Bistupur, Jamshedpur, Jharkhand-831001, India.
2. ARIJIT BISWAS
Tata Steel Ltd., Bistupur, Jamshedpur, Jharkhand-831001, India.
3. ADITYA ROSHAN
Tata Steel Ltd., Bistupur, Jamshedpur, Jharkhand-831001, India.
4. UMESH PRASAD RATH
Tata Steel Ltd., Bistupur, Jamshedpur, Jharkhand-831001, India.
5. GAJANAN U. KAPURE
Tata Steel Ltd., Bistupur, Jamshedpur, Jharkhand-831001, India.

Specification

Claims:I/We claim:
1. A blend for smelting chromite ore burden comprising:
sintered pellet, friable lump, chromium bearing magnesium silicate mineral, hard lump, quartzite, coke,
the sintered pellet comprising in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: 1 to 3, Cr (total): 30 to 35, Fe (total): 12-15 with Cr/Fe ratio 2.40 to 2.53;
the friable lump in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: < 0.5, Cr (total): 32 to 38, Fe (total): 13-15 with Cr/Fe ratio: 2.5 to 2.8;
the chromium bearing magnesium silicate mineral, in weight%, MgO: 30 to 36, Al2O3:1 to 3, SiO2:35 to 53, Cr2O3: 1 to 7, CaO: 0.5 to 1, Fe2O3: 2 to 6; and
the hard lump in weight%, MgO: 17 to 23, Al2O3:7 to 9, SiO2: 20 to 24, CaO: < 0.5, Cr (total): 16 to 24, Fe (total): 7-10 with Cr/Fe ratio: 1.8 to 3.2, quartzite and coke.

2. The blend as claimed in claim 1, wherein the blend comprises 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral.

3. A method for smelting of chromite ore comprising:
blending sintered pellet, friable lump, chromium bearing magnesium silicate mineral, hard lump, quartzite, coke,
the sintered pellet comprising in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: 1 to 3, Cr (total): 30 to 35, Fe (total): 12-15 with Cr/Fe ratio 2.40 to 2.53,
the friable lump in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: < 0.5, Cr (total): 32 to 38, Fe (total): 13-15 with Cr/Fe ratio: 2.5 to 2.8,
the chromium bearing magnesium silicate mineral, in weight%, MgO: 30 to 36, Al2O3:1 to 3, SiO2:35 to 53, Cr2O3: 1 to 7, CaO: 0.5 to 1, Fe2O3: 2 to 6,
the hard lump in weight%, MgO: 17 to 23, Al2O3:7 to 9, SiO2: 20 to 24, CaO: < 0.5, Cr (total): 16 to 24, Fe (total): 7-10 with Cr/Fe ratio: 1.8 to 3.2, quartzite and coke, and
the blend comprising 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral;
charging the blend in a closed type submerged arc furnace; and
maintaining furnace parameters at specific power consumption: 3.02 to 3.32, average charge resistance: 1.89 to 2.54, average power factor: 0.89 to 0.93, specific coke consumption: 0.485 to 0.525 and specific ore consumption: 1.94 to 2.13.
, Description:CHROMIUM BEARING MAGNESIUM SILICATE MINERAL AS ALTERNATIVE FLUX TO HARD LUMP CHROMITE ORE IN HIGH CARBON FERROCHROME PRODUCTION

TECHNICAL FIELD
[0001] The present disclosure, in general, relates to an alternative solution for hard lump chromite ore replacement in closed submerged arc furnace for high carbon ferrochrome production and, more particularly, to a blend and a method for smelting chromite ore.

BACKGROUND
[0002] Background description includes information that may be useful in understanding the present subject matter. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed subject matter, or that any publication specifically or implicitly referenced is prior art.
[0003] In commercial submerged arc furnaces for ferrochrome production, interior of a submerged arc furnace can be divided into different zones: (a) a loose charge packed bed zone at an upper part of the furnace, (b) a smelting region around electrode tips above a coke bed and/or a slag layer, (c) coke beds under the electrodes and/or between the electrodes and a furnace wall, (d) an inactive zone adjacent to the furnace wall and above the slag/metal layer, (e) a molten slag layer, and (f) a molten alloy layer at the bottom part of the furnace.
[0004] Most of the volume inside the submerged arc furnace is of loosely sinter burden. As the burden slowly descends from the top of the furnace to electrode tip, a small part of the solid-state reduction of chromite happen by the up moving carbon monoxide (CO) gas generated from the smelting zone and the coke bed zone. The main part of the reduction occurs in the coke bed zone which has a temperature of about 1700-1800 °C with an average retention time of 20 minutes for the materials.
[0005] Wewber and Eric studied the reduction mechanism of carbothermic reduction of natural chromite from Bushveld complex at 1300-1500 °C in the presence of silica flux. They established a two-stage reduction mechanism for the chromite reduction in the presence of silica flux. The first stage of reduction mostly limited to iron oxide reduction and the second stage of reduction is mostly confined to chromium oxide reduction. The first stage of reduction is dominantly diffusion controlled mechanism and indirect reduction up to 40 % of reduction can happen. Silica affects the reduction of chromite ore above 1400 °C through the formation of silicate slag. Further, the second stage of reduction in chromite ore is governed by chemical reaction controlled mechanism due to the dissolution of reducible cations in silicate slag and interaction of ions of reducible cations and the dissolved ions in the slag.
[0006] Wang et. al., 2015, studied the effects of calcium oxide (CaO), magnesium oxide (MgO), aluminium oxide (Al2O3), silicon dioxide (SiO2) on the carbothermic reduction of synthetic iron(II) chromite (FeCr2O4). The isothermal reduction study of synthetic FeCr2O4 at 1673 K revealed that CaO and Al2O3 favoured the reduction rate and the reduction degree due to favourable diffusion of Cr3+ in the solid phase. Ca2+ can easily replace Fe2+ which facilitated the ion diffusion in the solid phase. Similarly, Cr3+ easily replace Al+3 favouring diffusion of Cr+3 to the outer zone and Al+3 to the inner zone. MgO hinders the reduction due to the formation of more stable phase MgCr2O4. SiO2 did not affect in the initial reduction (Cr3+ was reduced to Cr+2), but it delayed the reduction in metallic stage (Cr2+ to Cr) as CrO and SiO2 form low melting phase which separate the Cr+2 ions from carbon and thus hamper the reduction.
[0007] Chen Yonggao further describes that MgO/Al2O3 ratio and SiO2 content in ferrochrome slag are key factors in determining melting point and viscosity of the slag. Increase in SiO2 content decreases the melting point of ferrochrome slag at Al2O3/MgO ratio < 2.2. For fixed SiO2 content, the melting point decreases with the increase of Al2O3/MgO ratio up to a certain value of the ratio, then decreases.
[0008] Accordingly, the melting behaviour of chromite ores, that affect the reduction and melting rates, depends on the structure of the ores and the properties of the gangue minerals. Chromium reduction is an auto-catalytic process. During smelting, the chromite ore disintegrates when the reduction is nearly complete and this accelerates the formation of slag.
[0009] Xu et. al. further describes that early slagging interrupts the carbon transfer and retards the formation of metal. So, in order to improve chromium recoveries, the melting rate should correspond to the reduction rate. It is suggested by the Xu et al. that the prevention of early slagging would improve the smelting operation.
[0010] Neuschiitz et. al. studied the effect of flux composed of 3 or 4 of components SiO2, CaO, Al2O3, MgO and CaF2 on the kinetics of South African chromite ore reduction with carbon. According to Neuschiitz et. al., reduction kinetics of chromite ores accelerated in the presence of fluxes and the reduction temperature can be lowered by up to 150 °C. In absence of the flux during chromite reduction, only single stage acceleration is observed while the presence of the lux during chromite reduction showed two-stage acceleration with temperature while there is only single stage acceleration observed in the absence of a flux. The first stage of acceleration started at 1020 to 1120 °C and attributed to solid state formation of ternary oxides. the second one started at 1200 to 1320 °C and attributed to the formation of liquid slag. The early slag formation enhances the chromite reduction by dissolving part of MgO.Al2O3 spinel around unreduced chromite, thereby accelerating transportation of chromium (Cr) ions to the reductant.
[0011] Dawson and Edwards indicated that the formation of very stable magnesio chromite spinel is the major factor for poor reduction rate and extend of reduction. Reduction of chromite ore and dissolution of spinel are interdependent. In chromite, reduction in presence of flux helps three phenomena: (a) dissolution of the spinel constituents, (b) the migration of ions through the liquid phase, and (c) the reaction at the reductant surface. According to Dawson and Edwards, a suitable flux composition should be such that:
i. It should have a liquidus temperature below that of the operating temperature,
ii. It can dissolve a substantial amount of Al2O3 without a dramatic increase in the solidus temperature.
iii. The melt formed should have low viscosity to permit the rapid diffusion of ions.
[0012] CN106521148A describes a method for preparing high carbon ferro-chrome by fusible chrome fine ore. The method comprises of screening chrome fines, pelletizing of chrome fines less than 6 mm, mixing of pellets with chromite ore of particle size >6mm, and reductant and flux before smelting in a submerged arc furnace. The process can use flux either one or more of silica, magnesite, and dolomite for production of high carbon ferro-chrome.
[0013] WO2012057593A1 describes briquettes made up of chromium ore of particle size less than 10 mm and carbonaceous reductant of size less than 5mm in the ratio of 1: (0.3-0.5) were smelted in presence of a carbonaceous reductant and quartz as flux. The charge that fed to the furnace during production was comprised of 93.7-96.2 wt% chromite briquettes and 3.8-6.3% quartzite respectively.
[0014] CN100392130C describes a one-step smelting technology which consists of feedstock of 100 % by weight chromite, 8-20% by weight silica, 4-10% by weight of the coke and 1.5% by weight of dolomite in submerged arc furnace for medium carbon ferrochrome.
[0015] US5654976A describes a method for melting ferrous scrap metal and chromite in a submerged arc furnace to produce chromium containing iron. The process feeds a mixture of 1-60% by weight of a scrap of chromite, about 1 to 20% by weight of a scrap of flux materials, about 5 to 35% by weight of scrap of carbonaceous material, about 0-10% by weight of scrap of wood chips to submerged arc furnace. US5654976A also described that quartzite, bauxite, lime, and magnesia containing material may be used as suitable flux materials in this process. Though disclosure of US5654976A used magnesium bearing material as flux, the process mentioned in the patent is for making chromium containing iron, not for ferrochrome.
[0016] Most of the above described prior arts mentioned used the quartzite, dolomite, and magnesite as flux material for the production of high carbon ferrochrome, but none has used chromium bearing magnesium silicate mineral as alternate to hard lump chromite ore. Chromium-bearing magnesium silicate type of ore is not suitable as a flux in iron making related application.
[0017] However, chromium-bearing magnesium silicate minerals will have many technical advantages if used as a replacement of hard lump chromite ore in the production of high carbon ferrochrome. Also, magnesium silicate bearing minerals are having a lower melting point than the chromite ore, so their use in a closed type of submerged furnace is limited as closed furnaces have limited access to the inside of furnace if any unusual furnace behaviour observed.

OBJECTS OF THE DISCLOSURE
[0018] In view of the foregoing limitations inherent in the state of the art, some of the objects of the present disclosure, which at least one embodiment herein satisfy, are listed herein below.
[0019] It is an object of the present disclosure to the replace the use of hard lump chromite ore by chromium bearing magnesium silicate mineral in production high carbon ferro chrome by carbothermic reduction process in a close submerged arc furnace.
[0020] This and other objects and advantages of the present invention will be apparent to those skilled in the art after a consideration of the following detailed description taken in conjunction with the accompanying drawings in which a preferred form of the present invention is illustrated.

SUMMARY
[0021] This summary is provided to introduce concepts related to a blend and a method for smelting chromite ore. The concepts are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
[0022] The present disclosure relates to a blend for smelting chromite ore burden. The blend includes sintered pellet, friable lump, chromium bearing magnesium silicate mineral, hard lump, quartzite, and coke. In an aspect, the sintered pellet comprising in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: 1 to 3, Cr (total): 30 to 35, Fe (total): 12-15 with Cr/Fe ratio 2.40 to 2.53; the friable lump in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: < 0.5, Cr (total): 32 to 38, Fe (total): 13-15 with Cr/Fe ratio: 2.5 to 2.8; the chromium bearing magnesium silicate mineral, in weight%, MgO: 30 to 36, Al2O3:1 to 3, SiO2:35 to 53, Cr2O3: 1 to 7, CaO: 0.5 to 1, Fe2O3: 2 to 6; the hard lump in weight%, MgO: 17 to 23, Al2O3:7 to 9, SiO2: 20 to 24, CaO: < 0.5, Cr (total): 16 to 24, Fe (total): 7-10 with Cr/Fe ratio: 1.8 to 3.2, quartzite and coke.
[0023] In an aspect, the blend comprises 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral.
[0024] The present disclosure further relates to a method for smelting of chromite ore. The method includes blending sintered pellet, friable lump, chromium bearing magnesium silicate mineral, hard lump, quartzite, and coke; charging the blend in a closed type submerged arc furnace; and maintaining furnace parameters at specific power consumption: 3.02 to 3.32, average charge resistance: 1.89 to 2.54, average power factor: 0.89 to 0.93, specific coke consumption: 0.485 to 0.525 and specific ore consumption: 1.94 to 2.13. In an aspect, the sintered pellet comprising in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: 1 to 3, Cr (total): 30 to 35, Fe (total): 12-15 with Cr/Fe ratio 2.40 to 2.53; the friable lump in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: < 0.5, Cr (total): 32 to 38, Fe (total): 13-15 with Cr/Fe ratio: 2.5 to 2.8; the chromium bearing magnesium silicate mineral, in weight%, MgO: 30 to 36, Al2O3:1 to 3, SiO2:35 to 53, Cr2O3: 1 to 7, CaO: 0.5 to 1, Fe2O3: 2 to 6; and the hard lump in weight%, MgO: 17 to 23, Al2O3:7 to 9, SiO2: 20 to 24, CaO: < 0.5, Cr (total): 16 to 24, Fe (total): 7-10 with Cr/Fe ratio: 1.8 to 3.2, quartzite and coke; and the blend comprises 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral.
[0025] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
[0026] The illustrated embodiments of the subject matter will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout. The following description is intended only by way of example, and simply illustrates certain selected embodiments of devices, systems, and methods that are consistent with the subject matter as claimed herein, wherein:
[0027] FIG. 1 illustrates a method for smelting of chromite ore in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION
[0028] The detailed description of various exemplary embodiments of the disclosure is described herein with reference to the accompanying drawings. It should be noted that the embodiments are described herein in such details as to clearly communicate the disclosure. However, the amount of details provided herein is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure as defined by the appended claims.
[0029] It is also to be understood that various arrangements may be devised that, although not explicitly described or shown herein, embody the principles of the present disclosure. Moreover, all statements herein reciting principles, aspects, and embodiments of the present disclosure, as well as specific examples, are intended to encompass equivalents thereof.
[0030] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of example embodiments. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes”, “consisting” and/or “including” when used herein, specify the presence of stated features, integers, steps, operations, elements and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and/or groups thereof.
[0031] It should also be noted that in some alternative implementations, the functions/acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may, in fact, be executed concurrently or may sometimes be executed in the reverse order, depending upon the functionality/acts involved.
[0032] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which example embodiments belong. It will be further understood that terms, e.g., those defined in commonly used dictionaries, should be interpreted as having a meaning that is consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.
[0033] Furthermore, as can be appreciated by those skilled in the art that carbothermic reduction is the dominating technology practiced worldwide for the production of high carbon ferrochrome alloy. Most commonly submerged arc furnaces are employed for the smelting of chromite ores by carbonaceous reductants in presence of flux. The sintered pellets along with hard and friable lumps are smelted in submerged arc furnace with coke reductant and fluxes. The chromite bearing burden consists of approximately 60-63% sintered pellet, 15-20% hard lump and 18-22% friable lump. Use of hard lump in ferrochrome production is due to following reasons: (a) as a source of MgO flux due to high MgO content, (b) good strength, and (c) as a source of chromium.
[0034] Availability of hard lump is scarce in many chromite mines. Hence, the sustainability of a plant operation without hard lump chromite ore is a challenge for the plant. Accordingly, chromium bearing magnesium silicate mineral as alternative flux has to replace hard lump in ferrochrome production in the closed furnace. The method proposed herein consists of blending of raw materials which consist of blending of 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral. The replacement of hard lump and addition blending of flux materials is selected in such a manner that the ratios such as MgO/Al2O3˜1, MgO+CaO/SiO2˜0.85 to 1 are maintained. The blended raw materials are smelted in a closed submerged arc furnace at approximately 1600-1700 OC for 2 to 3 hours. Chromium oxide reduction by carbon proceeds by multi-stage reduction process (Cr2O3 ?CrO ?Cr?Cr7C3) to form carbide. Reduction of Chromium oxide may occur by two possible reactions:
;
;
[0035] After the smelting process, the molten slag and metal are tapped from the furnace through the same tap hole. The ferrochrome slag, being lighter than ferrochrome alloy, collected at the top of the alloy and easily removed by decanting the top part. The composition of ferrochrome alloy consists of Cr; 60-62%, C: 6-8%, Si: 2-4%, P: 0.015-0.03. The furnace parameters such as specific ore consumption (coke, quartzite, chromite ore), specific power consumption, average load, average charge resistance, average power factor, alloy composition, slag basicity and input Cr/Fe ratio of burden were improved. The specific power consumption varies from 3.02 to 3.32, average charge resistance varies from 1.89 to 2.54, average power factor varies from 0.89 to 0.93, specific coke consumption varies from 0.485 to 0.525 and specific ore consumption varies from 1.94 to 2.13.
Example-1
[0036] The ore blend consisting of current ore blend of 60% pellet, 19 % hard lump, 14% Friable lump, 7% quartzite, the hard lump is replaced by the use of chromite bearing magnesium silicate mineral. The ore blend consists of 64% pellet, 9% hard lump, 18% Friable lump chromite, 6% quartzite, 3% pyroxenite replaces 47% hard lump usage.
Example-2
[0037] The ore blend consisting of current ore blend of 60% pellet, 19 % hard lump, 14% friable lump, 7% quartzite, and the hard lump is replaced by the use of chromite bearing magnesium silicate mineral. The ore blend consists of 66% pellet, 22% Friable lump chromite, 5% quartzite, 7% pyroxenite replaces 100% hard lump usage.
[0038] With the above examples and studies as the basis, the present disclosure proposed a method for smelting of chromite ore in accordance with an embodiment of the present disclosure.
[0039] FIG. 1 illustrates a method 100 for smelting of chromite ore in accordance with an embodiment of the present disclosure. The method 100 is suitable for both single-phase as well as multiphase steels. The order in which the method 100 is described is not intended to be construed as a limitation, and any number of the described method blocks may be combined in any order to implement the method 100, or an alternative method.
[0040] At block 102, the method 100 includes blending sintered pellet, friable lump, chromium bearing magnesium silicate mineral, hard lump, quartzite, and coke. In an aspect, the sintered pellet comprising in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: 1 to 3, Cr (total): 30 to 35, Fe (total): 12-15 with Cr/Fe ratio 2.40 to 2.53; the friable lump in weight%, MgO: 9 to 11, Al2O3:10 to 13, SiO2:5 to 7, CaO: < 0.5, Cr (total): 32 to 38, Fe (total): 13-15 with Cr/Fe ratio: 2.5 to 2.8; the chromium bearing magnesium silicate mineral, in weight%, MgO: 30 to 36, Al2O3:1 to 3, SiO2:35 to 53, Cr2O3: 1 to 7, CaO: 0.5 to 1, Fe2O3: 2 to 6; and the hard lump in weight%, MgO: 17 to 23, Al2O3:7 to 9, SiO2: 20 to 24, CaO: < 0.5, Cr (total): 16 to 24, Fe (total): 7-10 with Cr/Fe ratio: 1.8 to 3.2, quartzite and coke; and the blend comprises 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral.
[0041] At block 104, the method 100 includes charging the blend in a closed type submerged arc furnace.
[0042] At block 106, the method 100 includes maintaining furnace parameters at specific power consumption: 3.02 to 3.32, average charge resistance: 1.89 to 2.54, average power factor: 0.89 to 0.93, specific coke consumption: 0.485 to 0.525 and specific ore consumption: 1.94 to 2.13.
[0043] The present disclosure is related to the use of chromite bearing magnesium silicate mineral as an alternative flux to replace hard lumpy chromite ore in production high carbon ferro-chrome close submerged arc furnace. The method proposed herein broadly consists of blending of blending of 60-70 % sintered chromite pellet, 0-20% hard lump chromite ore, 14-22% friable lump chromite ore, 5-7% quartzite and 3-7% chromite bearing magnesium silicate mineral. Also, this use of alternative material in ferrochrome production improve productivity by lowering the specific ore, coke, and power consumption.
[0044] Further, the present disclosure is related to replacement of hard lump chromite mineral by chromium containing magnesium silicate mineral as flux alternative to hard lump chromite ore in production high carbon ferro chrome by carbothermic reduction process in a close submerged arc furnace. The blending of burden materials consists of blending of chromite ore (sintered pellet, friable lump, and hard lump) and blending of flux (Quartzite). The blending of chromite burden is selected in such a way that the Cr/Fe ratio (2.3-2.4) of burden remains similar after replacement of hard lump. Also, the blending of flux materials is selected in such a manner that the ratios such as MgO/Al2O3˜1, MgO+CaO/SiO2˜0.85 to 1 are maintained.
[0045] Furthermore, those skilled in the art can appreciate that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. It will be appreciated that several of the above-disclosed and other features and functions, or alternatives thereof, may be combined into other systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may subsequently be made by those skilled in the art without departing from the scope of the present disclosure as encompassed by the following claims.
[0046] The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others.
[0047] While the foregoing describes various embodiments of the present disclosure, other and further embodiments of the present disclosure may be devised without departing from the basic scope thereof. The scope of the present disclosure is determined by the claims that follow. The present disclosure is not limited to the described embodiments, versions or examples, which are included to enable a person having ordinary skill in the art to make and use the invention when combined with information and knowledge available to the person having ordinary skill in the art.

Documents

Application Documents

# Name Date
1 201931010722-STATEMENT OF UNDERTAKING (FORM 3) [19-03-2019(online)].pdf 2019-03-19
2 201931010722-POWER OF AUTHORITY [19-03-2019(online)].pdf 2019-03-19
3 201931010722-FORM 1 [19-03-2019(online)].pdf 2019-03-19
4 201931010722-FIGURE OF ABSTRACT [19-03-2019(online)].jpg 2019-03-19
5 201931010722-DRAWINGS [19-03-2019(online)].pdf 2019-03-19
6 201931010722-DECLARATION OF INVENTORSHIP (FORM 5) [19-03-2019(online)].pdf 2019-03-19
7 201931010722-COMPLETE SPECIFICATION [19-03-2019(online)].pdf 2019-03-19
8 201931010722-FORM 18 [22-03-2019(online)].pdf 2019-03-22
9 201931010722-Proof of Right (MANDATORY) [08-04-2019(online)].pdf 2019-04-08
10 201931010722-OTHERS [29-05-2021(online)].pdf 2021-05-29
11 201931010722-FER_SER_REPLY [29-05-2021(online)].pdf 2021-05-29
12 201931010722-COMPLETE SPECIFICATION [29-05-2021(online)].pdf 2021-05-29
13 201931010722-ABSTRACT [29-05-2021(online)].pdf 2021-05-29
14 201931010722-FER.pdf 2021-10-18
15 201931010722-RELEVANT DOCUMENTS [10-01-2023(online)].pdf 2023-01-10
16 201931010722-POA [10-01-2023(online)].pdf 2023-01-10
17 201931010722-FORM 13 [10-01-2023(online)].pdf 2023-01-10
18 201931010722-RELEVANT DOCUMENTS [16-05-2023(online)].pdf 2023-05-16
19 201931010722-POA [16-05-2023(online)].pdf 2023-05-16
20 201931010722-FORM 13 [16-05-2023(online)].pdf 2023-05-16
21 201931010722-US(14)-HearingNotice-(HearingDate-12-09-2023).pdf 2023-07-11
22 201931010722-Correspondence to notify the Controller [11-09-2023(online)].pdf 2023-09-11
23 201931010722-US(14)-ExtendedHearingNotice-(HearingDate-12-09-2023).pdf 2023-09-12
24 201931010722-Written submissions and relevant documents [27-09-2023(online)].pdf 2023-09-27
25 201931010722-PatentCertificate07-12-2023.pdf 2023-12-07
26 201931010722-IntimationOfGrant07-12-2023.pdf 2023-12-07

Search Strategy

1 SearchStrategy_201931010722E_28-11-2020.pdf

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