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The Si processDRAWINGS
Thorsteinn Hannesson
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The Si processDRAWINGS
Thorsteinn Hannesson
Elkem Iceland
May, 2016
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All the drawings in this book can be used at will in papers,presentations and other non-commercial publications,provided that proper references and credits are given. Thedrawings can not, however, be used for commercial purposeswithout a permission from the author.
An electronic version of the drawings is available at thewebsite of Elkem Iceland:
WWW. elkem.is
Thorsteinn Hannesson(E-mail: [email protected])
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INTRODUCTION
Silicon is an element that is in a number of materials around us. Silicon is making aluminium
alloys stronger. Silicon is the basis for silicones used in a number of everyday products like
pharmaceuticals, cosmetics, water-repellent impregnation and silicone rubbers to mention
only a few. As silicon is a semi-conductor, it is also used in all kinds of electrical equipment
like e.g. computers. Mixed with iron, silicon is used to a great extent to make high quality
steel. The most visible area is the use of silicon in silicon solar cells, which is the largest
growing area within silicon based products. The versatile element of silicon is hence used in
products all around us to improve the quality of life and to increase the production of
renewable energy.
The silicon production process is the starting point for all of these products. Silicon or
ferrosilicon is produced in large electrical furnaces from quartz and carbon materials like
charcoal and coal. The quartz will be transformed to liquid silicon through a high
temperature process of up to 2000 °C. The liquid silicon will then be cooled and solidified,
then crushed into suitable size.
Silicon has been produced at Iceland through decades, and during the last years Iceland is
coming up as one of the world leading countries regarding silicon production. During many
years, Thorsteinn Hannesson, has worked in the silicon producing company Elkem Iceland.
His ability to transfer technical knowledge through artistic drawings of the silicon process
has both increased the knowledge within the company but also externally. It is hence a
happy day for all us fans of silicon and its production process to see the work of Thorsteinn
Hannesson collected in this book. This will also give a possibility to transfer the knowledge
to the upcoming new generation.
Prof. Merete Tangstad
Norwegian University of Science and Technology
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THE FERROSILICON FURNACE
A submerged, three phase electrical arc furnace with self-baking Søderbergelectrodes.
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THE MAIN REACTIONS
QUARTZ CARBON SILICON CARBON MONOXIDE
SiO2 2 C Si 2 CO
ENERGY
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THE SI PROCESS
Si
2 CO + O2 = 2 CO22 C + SiO2
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THE SI PROCESS
07.09.2016
2 C + SiO2
Si
2 CO + O2 = 2 CO2
Outer reaction zone
1550 °C
Inner reaction zone
over 1800°C
(crater zone)
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THE SI PROCESS
SiO(g) + 2C = SiC + CO
SiO2 + SiC = Si + SiO(g) + CO
SiO2 (quartz)
Metal
C coal / coke
CO2
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THE PRODUCTION PROCESS
Loading/ Raw material storage Transport to furnace bins
unloading
Weigh bridge Microsilica® storage Filter Coolers
FeSi storage Screening Crushing Casting Furnace
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RAW MATERIALS - HANDLING AND STORAGE
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RAW MATERIALS - SCREENING AND TRANSPORTATION
TO FURNACE BINS
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CRUSHING SCREENING AND STORAGE
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CASTING IN CAST IRON MOLDS
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BED CASTING
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BELT CASTING
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COOLERS AND BAG HOUSE FILTER
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WEIGHING OF THE FINAL PRODUCT - SHIPPING
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REFINING OF METAL
Tapping Slag refining Slag skimming
stirring
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ALLOYING
Alloying is done by
adding alloying elements
to the molten metal and
stirring the melt by e.g.
nitrogen purging.
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THE USE OF NATURAL RESOURCES - ENVIRONMENTAL IMPACT
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THE USE OF NATURAL RESOURCES - ENVIRONMENTAL IMPACT
All industrial activities are bound to
have impact on the environment.
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THE USE OF NATURAL RESOURCES - ENVIRONMENTAL IMPACT
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THE USE OF NATURAL RESOURCES - ENVIRONMENTAL IMPACT
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THE USE OF NATURAL RESOURCES - ENVIRONMENTAL IMPACT
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THE USE OF NATURAL RESOURCES - ENVIRONMENTAL IMPACT
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THE USE OF NATURAL RESOURCES
The production of 120.000 MT/year of FeSi 75
Annual usage of raw materials and production in correct proportions. The
highest stock pile is 52 m high.
Quartz Iron Coal Coke Woodchips FeSi Microsilica®
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RAW MATERIALS
Raw materials are costly so those should be handled with care.
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THE SØDERBERG ELECTRODE
Cross section Current paths Slipping
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THE SØDERBERG ELECTRODE - ELECTRODE BREAKAGES
Hard break Soft break - paste leakage
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THE SØDERBERG ELECTRODE - SEGREGATION IN
THE LIQUID PASTE
Segregation in the
electrode column
Normal paste
Segregated paste
Binder
Aggregate
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THE USE OF FERROSILICON
Ferrosilicon is mostly used as a deoxidizing agent, as an additive in the
production of steel and as nodulizer and inoculant in iron foundries.
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The author
Thorsteinn Hannesson war born in Reykjavik, Iceland. He finished
his BS in Chemistry from the University of Iceland and PhD in
Physical Chemistry from the University of Michigan. He works at
Elkem Iceland as a Senior Specialist.
(E-mail: [email protected])
Credits and acknowledgements
I would like to express my sincere thanks to Professor Merete
Tangstad at the Norwegian University of Science and Technology
in Trondheim in Norway for suggesting this work and for her
continuous support. I would also like to express my thanks to the
Research Counsel of Norway or financial support through the
Resina Project
Thorsteinn Hannesson