Aluminium thermal reduction process for preparing ferrosilicon and alumina from fly ash
J. Min. Metall. Sect. B-Metall., 62 (1) (2026) 1-12. DOI:10.2298/JMMB250715001S
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Available online 08 maj 2026
(Received 15 July 2025; Accepted 25 March 2026)
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There has been a focus on environmental protection and the recycling of solid waste resources, particularly fly ash and aluminum dross. Efforts to utilize fly ash efficiently have increased. In this paper, a process is introduced for producing alumina-rich slag and ferrosilicon alloy through aluminothermic reduction of fly ash with aluminium dross. Scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDS) confirm the formation of spherical ferrosilicon alloy encased in a loose, porous alumina matrix during the aluminothermic reduction process. Thermodynamic calculations indicated that the reduction temperature of SiO2 and mullite decreases in the presence of Fe2O3. Under conditions of 1673 K, a specific aluminium dross to fly ash ratio (A/F), and a reduction time of 20 minutes, the magnetic fraction contains 85.89% ferrosilicon, while the non-magnetic fraction has an alumina content of 79.42%. This process offers a solution with potential environmental and economic benefits for the application of fly ash and aluminum ash.
Keywords: Fly ash; Aluminum dross; Aluminum thermal reduction; Ferrosilicon alloy
Correspondence Address:
Qingchun Yu; Xiaomei Zhu,
National Engineering Research Center of Vacuum Metallurgy, Kunming University of Science and Technology, Kunming, China; Faculty of Metallurgical and Energy Engineering, Kunming University of Science and Technology, Kunming, China; Faculty of Chemical Engineering, Ordos Institute of Technology, Ordos, China;
email: yqcy@163.com; reozhuxm@163.com
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