Ferrosilicon:

Ferrosilicon is a ferroalloy, an alloy of iron and silicon with average silicon content between 15 and 90 weight percent. It contains a high proportion of iron silicides.

Chemistry:

Ferrosilicon is produced by reduction of silica or sand with coke in presence of scrap iron, millscale, or other source of iron. Ferrosilicon with silicon content up to about 15% is made in blast furnaces lined with acid fire bricks. Ferrosilicon with higher silicon content is made in electric arc furnaces. The usual formulations on the market are ferrosilicon with 15%, 45%, 75%, and 90% silicon. The remainder is iron, with about 2% consisting of other elements like aluminum and calcium. An overabundance of silica is used to prevent formation of silicon carbide. Microsilica is a useful byproduct. A mineral perryite is similar to ferrosilicon, with its composition Fe5Si2.The melting point and density of ferrosilicon depends on its silicon content. In contact with water, ferrosilicon may slowly produce hydrogen.

Useage:

Ferrosilicon is used as a source of silicon to reduce metals from their oxides and to deoxidize steel and other ferrous alloys. This prevents the loss of carbon from the molten steel (so called blocking the heat); ferromanganese, spiegeleisen, silicides of calcium, and many other materials are used for the same purpose. It can be used to make other ferroalloys. Ferrosilicon is also used for manufacture of silicon, corrosion-resistant and high-temperature resistant ferrous silicon alloys, and silicon steel for electromotors and transformer cores. In the manufacture of cast iron, ferrosilicon is used for inoculation of the iron to accelerate graphitization. In arc welding, ferrosilicon can be found in some electrode coatings.

Ferrosilicon is a basis for manufacture of prealloys like magnesium ferrosilicon (MgFeSi), used for modification of melted malleable iron. MgFeSi contains 3–42% magnesium and small amounts of rare earth metals. Ferrosilicon is also important as an additive to cast irons for controlling the initial content of silicon. Ferrosilicon is also used in the Pidgeon process to make magnesium from dolomite.

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