A method for preparing low-aluminum electrically fused mullite products and ferrosilicon alloy from coal gangue

By melting coal gangue and aluminum-rich raw materials at high temperature in a DC electric arc furnace and controlling the reduction dosage, the efficient separation of impurity iron from the target product is achieved, solving the purity and energy consumption problems in the preparation of mullite products from coal gangue, and producing high-performance low-aluminum electrofused mullite products and ferrosilicon alloys.

CN122277236APending Publication Date: 2026-06-26UNIV OF SCI & TECH BEIJING +1
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Patent Information

Authority / Receiving Office
CN · China
Patent Type
Applications(China)
Current Assignee / Owner
UNIV OF SCI & TECH BEIJING
Filing Date
2026-03-13
Publication Date
2026-06-26

AI Technical Summary

Technical Problem

In existing technologies, the preparation of mullite products from coal gangue suffers from problems such as difficulty in effectively separating impurities, low product purity, high energy consumption, and difficulty in controlling the amount of reducing agent added, leading to fluctuations in product performance and increased costs.

Method used

A DC electric arc furnace is used to mix and melt coal gangue, aluminum-rich raw materials and reducing agent at 1800~2000℃. By precisely controlling the dosage of reducing agent, Fe2O3 is reduced to metallic Fe and alloyed to form ferrosilicon alloy, achieving efficient separation of impurity iron from target product. Combined with waste heat recovery and utilization, the process flow is simplified.

Benefits of technology

This method produces low-alumina electrofused mullite products with high purity and high bulk density, simplifies the process, reduces energy consumption, avoids secondary pollution, and enables the resource recovery of iron impurities.

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Abstract

This invention provides a method for preparing low-alumina fused mullite products and ferrosilicon alloys from coal gangue, belonging to the field of refractory materials technology. The method includes: mixing coal gangue, alumina-rich raw materials, and a reducing agent; melting the mixture; and then separating the mixture to obtain low-alumina fused mullite products and ferrosilicon alloys. The molar ratio of C in the reducing agent to the total Fe2O3 in the coal gangue and alumina-rich raw materials is (3.5~6.5):1; the melting temperature is 1800~2000℃. This invention utilizes a high reaction temperature, allowing for a complete reaction between Al2O3 and SiO2. By precisely controlling the amount of reducing agent added, Fe2O3 in the coal gangue is reduced to Fe, which then alloys with the reduced Si to form a ferrosilicon alloy. This achieves efficient separation of impurity iron from the product in the molten state, thereby improving the purity of the low-alumina fused mullite products.
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