An Innovative Safe Process for Producing Magnesium–Ferro–Silicon (MgFeSi) Alloy Containing Calcium and Rare Earth Elements

Abstract Magnesium has been used to enhance the mechanical properties of cast iron and is currently added in the production process as magnesium–ferro–silicon (MgFeSi) alloy to produce ductile cast iron. Several methods have been used to produce magnesium–ferro–silicon alloy. Most of these methods, either by reduction of dolomite or ferrosilicon and magnesium remelting processes, have faced technical problems in addition to the lower magnesium recovery. In the present study, a process has been innovated to produce magnesium–ferro–silicon alloy by coating the magnesium ingots with protective layer of fluxing materials to slow down the reaction of magnesium and liquid ferrosilicon and reduce the oxidation reaction of magnesium with the result of higher magnesium recovery. The innovative process proved efficiency in attaining higher magnesium recovery of 87.35%, higher rare earth elements recovery of 99.59% and producing magnesium–ferro–silicon alloy containing 9.58% Mg, 1.26% rare earth elements (REE) and 1.52% Ca (by weight) in a safe manner.