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Steam Explosions of Single Drops of Molten Silicon-Rich Alloys

Commercial quantities of ferrosilicon alloys and silicon metal in the form of granules are available. They are produced in water granulation, a process involving the risk of large-scale steam explosions. To learn about these steam explosions, we have investigated single drops of molten alloys when released into water. When single drops of molten ferrosilicon alloy with 75 wt.% Si (FeSi75) or silicon metal at its liquidus or melting temperature were released into cold, room temperature or hot water, spontaneous explosions never occurred. We could, however, initiate steam explosions by exposing the drops to upwarddirected pressure transients generated in the water with an encapsulated impactor. For water at room temperature, we determined (a) the strength of the pressure transients needed to initiate the steam explosion of a single drop, and (b) the range of fall depths over which the drop can be triggered to explode with this transient. When varying the water temperature we learned that the triggered explosions became less vigorous as the temperature increased. The explosions became more vigorous also when the Al and/or Ca content in the molten drop decreased. Photographic images of the bubbles generated during the steam explosions indicate that the maximum energies released correspond to about 1 % to 2% (dependent on drop size) of the total enthalpy of the molten ferrosilicon at its liquidus temperature. During the explosions, tiny bubbles of a permanent gas, presumably hydrogen, were generated. Video images show that ferrosilicon drops with diameters between 3 mm and 11 mm fall through water at about 0.5 m/s. Shutter wheel photographs confirm these fall rates and also indicate the onset of solidification of the drops and show that steam explosions can occur in partially solidified drops.