How Calcium Silicon (CaSi) Is Produced?

1. Raw Materials Selection

The production of calcium silicon begins with the careful selection of raw materials. The primary raw materials used in this process include:

• Silicon dioxide (SiO2): Commonly sourced from quartz or silica.
• Calcium oxide (CaO): Derived from limestone or lime.
• Coke: Used as a reducing agent during the production process.

These raw materials are chosen for their purity and quality, as the effectiveness of the calcium silicon alloy largely depends on the composition of these elements.

2. Smelting in Submerged Arc Furnace

Once the raw materials are selected, they are charged into a submerged arc furnace (SAF). This furnace operates at extremely high temperatures, usually above 1,500°C. The key steps in this stage include:

• Reduction: The carbon from coke reacts with silicon dioxide (SiO2) to produce silicon (Si) in its elemental form. Similarly, calcium oxide (CaO) is reduced to form calcium (Ca).
• Formation of Calcium Silicon Alloy: As both silicon and calcium are formed in the furnace, they combine to form the calcium silicon alloy (CaSi).

The chemical reaction can be represented as: SiO2+2C→Si+2COSiO_2 + 2C → Si + 2COSiO2​+2C→Si+2CO $CaO+C\to Ca+CO$ $Ca+Si\to CaSi$

3. Tapping and Cooling

Once the smelting process is complete, the molten calcium silicon alloy is tapped from the furnace. The molten material is poured into molds, where it cools and solidifies. During cooling, the alloy is formed into blocks or other specified shapes, depending on the customer’s needs.

4. Crushing and Sizing

After the calcium silicon alloy has cooled and solidified, it is crushed and sized according to the requirements of the final product. The sizing process ensures that the alloy is in the right form for industrial applications, typically as lumps or granules.

Customers often require specific sizes, such as:

• CaSi 30/60 mesh for steelmaking applications.
• CaSi granules for foundry use.

5. Quality Control

Strict quality control measures are followed throughout the production process. This involves:

• Chemical Analysis: Ensuring that the calcium and silicon contents meet industry standards.
• Impurity Removal: Monitoring and minimizing impurities like phosphorus (P) and sulfur (S) that can affect the alloy’s performance in steelmaking.

Advanced equipment like spectrometers is used to verify the chemical composition, ensuring that every batch meets the required specifications.

6. Packaging and Shipping

After production and quality control, the calcium silicon is packaged in various forms, such as:

• Jumbo bags (for large quantities).
• Smaller bags (for easy handling).

The product is then prepared for shipping to customers globally, ensuring it is delivered on time and in the best condition.

Applications of Calcium Silicon

Calcium silicon plays an essential role in a wide range of metallurgical processes, particularly in:

• Steelmaking: Used as a deoxidizer and desulfurizer to produce cleaner steel with better mechanical properties.
• Cast Iron: Helps improve the graphite structure, resulting in stronger, more durable castings.
• Ferroalloy Production: Calcium silicon is often added to ferroalloys to enhance their performance in various industrial processes.

The production of calcium silicon is a highly technical and controlled process, ensuring that this vital alloy meets the demands of industries worldwide. From raw material selection to quality control, each stage is designed to produce high-quality calcium silicon that enhances the efficiency of steelmaking and foundry processes.

If you’re interested in learning more about our calcium silicon products or placing an order, please contact us today!