The appropriate particle size of ferrosilicon is crucial for efficient steelmaking operations, as it directly impacts melting rate, yield, and energy consumption. For instance, large blocks (10-80mm) are ideal for converter charging carts, while the standard particle size range (3-10mm) is optimized for electric arc furnace feeding systems. Additionally, fine powder (200 mesh) serves as an additive in electrode coatings. A notable case is a Malaysian steel mill that switched from aluminum deoxidation to ferrosilicon with a granular size of 3-8mm. This change resulted in significant improvements: deoxidation time was reduced from 8.5 to 5.2 minutes, consumption of ferrosilicon per ton of steel decreased from 6.8kg to 5.9kg, and electrode consumption dropped by 1.2kg per ton. These enhancements generated an annual comprehensive benefit of $2.1 million, with an investment payback period of just 67 days.
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