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<p>The annual discharge of coal gasification coarse slag is substantial, and its high-value utilization is of great significance for resource recovery and environmental protection. To explore efficient resource recovery pathways, this study innovatively proposes a technical strategy for producing ferrosilicon alloy from coal gasification coarse slag, systematically comparing the efficiency and mechanisms of two smelting processes: medium-frequency induction furnace and electric arc furnace. The results show that under optimized medium-frequency induction furnace conditions (1800&#xa0;°C, 25&#xa0;min holding time, and carbon addition of 80% of the theoretical value), the maximum alloy recovery rate reached 27.80 wt% with a silicon content of 30.14 wt%. In contrast, the electric arc furnace process significantly improved the alloy quality, achieving a silicon content of 40.68 wt%, which approaches the commercial 45% ferrosilicon standard. Mechanistic analysis reveals that the high-temperature environment in the electric arc furnace synergistically promotes silicon enrichment through the following pathways: (1) accelerating the generation of gaseous SiO; (2) enhancing the conversion efficiency of SiC intermediates; (3) promoting the transformation of the Fe–Si system into the high-silicon FeSi<sub>2</sub> phase, thereby achieving deep reduction. This work not only provides a novel approach for the high-value utilization of coal gasification coarse slag but also offers theoretical and technical support for the resource recycling and low-carbon transformation of metallurgical solid waste.</p>

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A novel Process for Preparing Ferrosilicon Alloy from Coal Gasification Coarse Slag

  • 期刊论文

  • 发表日期：

    2026年1月7日

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  • Chuang Liu,
  • Shuyi Yao,
  • Xinhe Yang,
  • Chaobo Tang,
  • Pengfei Xing

摘要

The annual discharge of coal gasification coarse slag is substantial, and its high-value utilization is of great significance for resource recovery and environmental protection. To explore efficient resource recovery pathways, this study innovatively proposes a technical strategy for producing ferrosilicon alloy from coal gasification coarse slag, systematically comparing the efficiency and mechanisms of two smelting processes: medium-frequency induction furnace and electric arc furnace. The results show that under optimized medium-frequency induction furnace conditions (1800 °C, 25 min holding time, and carbon addition of 80% of the theoretical value), the maximum alloy recovery rate reached 27.80 wt% with a silicon content of 30.14 wt%. In contrast, the electric arc furnace process significantly improved the alloy quality, achieving a silicon content of 40.68 wt%, which approaches the commercial 45% ferrosilicon standard. Mechanistic analysis reveals that the high-temperature environment in the electric arc furnace synergistically promotes silicon enrichment through the following pathways: (1) accelerating the generation of gaseous SiO; (2) enhancing the conversion efficiency of SiC intermediates; (3) promoting the transformation of the Fe–Si system into the high-silicon FeSi2 phase, thereby achieving deep reduction. This work not only provides a novel approach for the high-value utilization of coal gasification coarse slag but also offers theoretical and technical support for the resource recycling and low-carbon transformation of metallurgical solid waste.