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<p>A novel process was developed to enhance magnesium recovery in ferrosilicon-magnesium alloy production by coating magnesium ingots with a mixture of ferrosilicon fines, dolomite ore, talc ore, and boric acid. A factorial design model was used to assess the impact of the coating materials and magnesium additions on recovery and content in the alloy. In a pilot plant electric arc furnace, a charge of ferrosilicon alloy and steel scrap was melted at 1600&#xa0;°C, with magnesium ingots added into a preheated ladle. Four experiments were conducted with 9 and 10% magnesium additions, two without coatings, and two with 90% of the ingots coated (30–33% of total magnesium weight). Results showed that coating increased magnesium recovery from 36.55 to 78.75% at 9% magnesium addition, and from 56.08 to 85.44% at 10%. The factorial design model, analyzed with MATLAB, accurately predicted magnesium content and recovery, demonstrating its effectiveness in optimizing the production of ferrosilicon-magnesium alloy. </p>

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Prediction of Mg-Recovery and Mg-Content in an Innovative Production Process of FeSiMg Alloy

  • 期刊论文

  • 发表日期：

    2025年6月5日

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  • Mamdouh Eissa,
  • Hoda El-Faramawy,
  • Mahmoud Nasr,
  • Azza Ahmed,
  • Hossam Halfa,
  • Mohamed El-Fawkhry,
  • Esraa Kotb,
  • Saeed Ghali

摘要

A novel process was developed to enhance magnesium recovery in ferrosilicon-magnesium alloy production by coating magnesium ingots with a mixture of ferrosilicon fines, dolomite ore, talc ore, and boric acid. A factorial design model was used to assess the impact of the coating materials and magnesium additions on recovery and content in the alloy. In a pilot plant electric arc furnace, a charge of ferrosilicon alloy and steel scrap was melted at 1600 °C, with magnesium ingots added into a preheated ladle. Four experiments were conducted with 9 and 10% magnesium additions, two without coatings, and two with 90% of the ingots coated (30–33% of total magnesium weight). Results showed that coating increased magnesium recovery from 36.55 to 78.75% at 9% magnesium addition, and from 56.08 to 85.44% at 10%. The factorial design model, analyzed with MATLAB, accurately predicted magnesium content and recovery, demonstrating its effectiveness in optimizing the production of ferrosilicon-magnesium alloy.