Ferro Vanadium, FerroTitanium, Vanadium Penta Oxide?

Question

what are the manufacturing processes & the raw materials

Answer 1

Manufacturing process :

The Ferro Silicon is manufactured in electric operated submerged arc furnace The manufacturing process of Ferro Silicon can be broadly classified into four steps.

a) Blending of raw materials

b) Charging and smelting in the arc furnace

c) Tapping and cooling of molten materials

d) Breaking, Cleaning and packing .



a) Blending of Raw Materials:

Quartz, Charcoal and M.S. scrap are mixed in the required quantity and lifted to the charging platform with the help of the lifting arrangements. The raw materials are generally mixed in the following proportion in terms of weight.

Quartz - 53 %

Charcoal - 35%

M.S. Scrap - 12%

b) Charging of raw materials:

The blended raw materials are charged to the furnace with the help of hoist and charging chutes at a regular interval. In the furnace three carbon electrodes are partially submerged in the charge , which are supported by hydraulic cylinders for upward and down ward movements . The electrodes helps in maintaining desired electric conditions in the furnace. The chemical reaction starts at a temperature of 1600 C. to 1700 C. In the reaction zone of the furnace the silica reacts with the reductants and after reaction, a mixture of iron and silicon trickles down and gets collected at the bottom of the furnace crucible. The impurities present in the form of molten slag are collected in vessel.

c) Tapping and cooling .

Three tap holes are provided at the bottom of the furnace for tapping both molten alloys and slag. During repair work of the Tap hole functions and the other works as standby .

As the charge enters the smelting zone, the alloy formed by chemical reactions of the oxides and the reductant, being heavy, gradually settles at the bottom. At a regular intervals of 2 to 2.5 hours the furnace is tapped. The tap hole is opened by Oxygen lancing pipe and after tapping is completed, it is closed by clay plugs. The liquid Ferro silicon is collected in the tapping pot and cast on the dressed sand beds for solidification and cooling.

d) Breaking cleaning and packing .

After solidification the cakes are broken manually with help of hammers to reduce to the required lump sizes after being removal of undesired particles if any, like slag contents etc., After cleaning and breaking laboratory test in conducted for checking quality and composition. Finished goods are then packed in either jute bags/ P.P. bags ready for dispatch.
Product Raw-materials

Unslaked Lime : Limestone and Coal

Hydrated Lime : Unslaked Lime and Water

Cement : Limestone + Clay + Coke-breeze = Clinker + Gypsum = Cement

Alum : Alumina-Hydrate,Bauxite,Sulphuric Acid

Ferro-silicon : Quartz,Charcoal,Mild steel Scrap,Electricity

Acid slurry : Linear Alkyle Benzene (LAB),Sulphuric Acid

Answer 2

The processes would be similar to most of refined metal procedures although some may use a catalyst to initiate the chemical reactions
Smelt and refine basic metal ore
combine those metals in a furnace of the required temp with necessary catalyst
the raw materials would be the ores of these metals (look up on web for commercial ores of Iron, Vanadium and Titanium also catalysts)
This is not a very complete answer but the alloys asked for do have slightly different processes and it is difficult to explain the details in a short answer