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The Plasma Production of Ferro Molybdenum — Process Development and Economics
 

The production of ferro molybdenum by the plasma decomposition of molybdenite concentrate to molybdenum and sulfur is used to illustrate the industrial application of plasmas to metallurgical processes. This process has stringent requirements for very high sulfur elimination (<0.15% S in the product) and low specific energy consumption in order to be competitive with the conventional process (roasting to the oxide, followed by thermite reduction). Direct-current transferred arcs appear to offer the most promising approach to the design of commercial reactors for this application.

Following a brief review of the development work on the thermal decomposition of molybdenite, a process flowsheet and the results of an economic assessment for a commercial plant are presented. The latter show the relative cost breakdown between key process units. The sensitivity of costs to factors such as scale of operation, specific energy consumption and electricity prices, raw materials, gas system (recycle versus once-through), and product recovery is illustrated. It is concluded that, while the plasma generator/reactor may be the technical heart of the overall process, industrial development programs must consider the capital and operating costs of a complete plant, including peripheral equipment and product marketing, as well as the duration, cost, and risk associated with the development project.

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