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Thermodynamic assessment of boron distribution and temperature characteristics during electric smelting separation of siderite concentrate with colemanite

Alexander Vusikhis, Kirill Pikulin, Stanislav Tyushnyakov, Kseniya Rybalchenko, Sergey Pikalov

Abstract


Siderite ores with high magnesium content are poorly amenable to conventional beneficiation, which limits their use in metallurgy. A promising processing method is electric smelting separation of metallized concentrate with calcined colemanite added as a flux to reduce the melting temperature of high‑magnesia slags. One issue is the potential reduction of boron from the slag into the metal. In this work, thermodynamic simulation in FactSage 7.0 is used to evaluate boron distribution between metal and slag. Calculations employ a four-factor experimental design according to the method of V.P. Malyshev. The variables include the SiO2/MgO ratio, the degree of metallization, the colemanite fraction, and the carbon content. Adding 10–15% colemanite reduces the slag liquidus temperature by 200–400 °C. Optimal regimes that ensure a slag liquidus temperature not exceeding 1450 °C and boron transfer to the slag above 95.3% are determined. At 95% metallization (SiO2/MgO = 1.5, colemanite 14.0%), boron transfer is 95.3–100% and the liquidus temperature is 1318–1406 °C. At 85% metallization, up to 2% carbon, SiO2/MgO of 1.4–1.5, and ~14.0% colemanite, boron‑free metal (B = 0.0%) is obtained. At 6% carbon, impurities increase (B up to 0.14%, Si up to 5.7%), yet the slag liquidus remains below 1447 °C. Reducing metallization to 75% yields boron‑free metal even at 6% carbon. These results provide a basis for developing an industrial technology for processing siderite ores by electric smelting separation.

Keywords


siderite concentrate; electric smelting separation; boron distribution; liquidus temperature; colemanite; thermodynamic simulation

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References


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DOI: https://doi.org/10.15826/chimtech.10401

Copyright (c) 2026 Alexander Vusikhis, Kirill Pikulin, Stanislav Tyushnyakov, Kseniya Rybalchenko, Sergey Pikalov

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