An Overview of Currently Applied Ferrochrome Production Processes and Their Waste Management Practices

Ferrochrome (FeCr) is the main source of virgin chromium (Cr) units used in modern-day containing alloys. The vast majority produced Cr during production stainless steel, which owes its corrosion resistance mainly to presence Cr. In turn, steel from Cr-containing scrap metal and FeCr, a relatively crude alloy between iron (Fe) FeCr an energy material-intensive process, wide variety by-products, typically classified as waste materials by industry, are created production. type extent generation dictated smelting route management practices thereof employed specific smelter. some cases, hazardous non-hazardous may be insufficient. Hazardous materials, such hexavalent Cr, i.e., Cr(VI), -containing wastes, only partially mitigated. Additionally, energy-containing carbon monoxide (CO)-rich off-gas, discarded, energy-invested fine oxidative sintered chromite, either stockpiled or sold ordinary chromite. cases where low-value wastes generated, rejects ore beneficiation processes, consistent efficient processes difficult employ return on investment not economically viable. More so, development less (C)-intensive (e.g., partial replacement C reductants) low-temperature pellet curing currently considered South African industry. reasoning for this due increased operation costs (if improved were implemented/higher cost reductants used) lack research initiatives. These reasons result stagnation technologies. From environmental point view, industries pressured reduce emissions. An attractive approach removing oxygen target oxides, mitigation gaseous C, using hydrogen reductant. By doing water vapor by-product. It however expected that stable Cr-oxide present will significantly more resistive hydrogen-based reduction when compared Fe-oxides. review, various industry summarized detail, per process step identified. limitations current regimes possible alternative routes discussed applicable. Various identified could improved, utilizing associated with CO-rich off-gas combustion, employing chromite pelletization considering potential further alterative processes/approaches proposed.