CROSS REFERENCE TO RELATED APPLICATIONS

[0001] The application takes priority to Indian patent application no. 202141048110 entitled APPARATUS AND METHOD FOR PRODUCING FERROSILICON filed on 22 October, 2021.

FIELD OF THE INVENTION

[0002] The present invention generally relates to metal extraction process, and in particular to environmentally friendly process for producing ferrosilicon or silicon.

DESCRIPTION OF THE RELATED ART

[0003] Ferro alloys are compounds of elements like silicon, manganese, chrome etc. They are used as additives during steel making and perform the dual function of removing impurities from the steel and modifying properties of the metal.

[0004] In the iron and steel industry, silicon plays a very important role. In steel making, it is one of the principal deoxidants and is used on a large scale as an alloying element in proportions. In conjunction with chromium and manganese, it is used in spring and valve steels and is used almost exclusively as the alloying element in electrical sheets for dynamos, motors and transformers. In electrical sheets, silicon steel shows the lowest hysteresis and eddy-current losses.

[0005] In cast irons it is a powerful graphitising agent and is added to grey and ductile iron up to 3% depending upon the initial silicon content of the iron. For instance, if a cast iron is made principally by the melting and re-carburization of steel scrap then most of the silicon up to 3% must be added as a silicon-containing alloy. High silicon cast iron containing 14% to 15% Si are quite widely used for acid resisting applications. Current global annual production of ferrosilicon and metallurgical grade silicon metal is estimated at 8-8.5 million tons. [0006] The principal raw material is the oxide of silicon (S1O ₂ ) normally referred to as silica, and this occurs widely in nature in many forms. The minerals which are principally of interest in this connection are crystalline quartz, quartzite and certain metamorphosed sandstones. When making ferrosilicon, the requirement is generally +98.5% SiO ₂ with certain limitations on the alumina, calcium and phosphorous contents.

[0007] Another important consideration is the number of fines produced on crushing of the quartz, as this will affect the amount of rock that has to be mined and quarried to produce the furnace feed, which should be approximately 2½ ”xl” (62.5x25mm) with all fines screened out, minus 3/8” (9mm).

[0008] Fines cannot be tolerated in a submerged electric arc furnace mix because they segregate, and what is more important is that they reduce the porosity of the charge causing premature fusion and crusting, which results in a build-up of gas pressure, the production of which is called “blows”. These take the form of a sudden release of high- temperature gas consisting of CO and SiO, which means a loss of silicon and reduction of overall efficiency.

[0009] In the making of ferrosilicon alloys, the iron is mostly added as scrap. Iron ore is rarely used because it tends to form slag with the silica before the iron is completely reduced, and it can introduce unwanted elements, such as phosphorous, calcium and aluminium.

[0010] Various carbon-bearing materials may be used as reducing agents in ferrosilicon production, mainly wood charcoal, processed lignite coal (LECO), or as a mix having the tolerable level of impurities to suit furnace operation.

[0011] Ferrosilicon is manufactured in a submerged electric arc furnace by reducing quartz (SiO ₂ ) with carbon. Steel scrap is added as an alloying element. The chemical reaction takes place at a temperature of around 2000 degrees centigrade, which the submerged electric arc furnace provides. The molten ferrosilicon is tapped out of the electric furnace at periodical intervals. The chemical composition of ferrosilicon of major global consumption is of the following two grades:

[0012] Ferrosilicon or Fe-Si alloy is typically produced using submerged arc furnaces. Raw materials used for the production of Fe-Si alloy are low alumina content quartz (SiO ₂ ) of 98.5-98.8% purity, steel scrap and wood charcoal with low ash content which serves as the reducing agent. Quartz with low alumina content is used.

[0013] Typical setup of a 15 MVA submerged arc furnace taking power from a substation is discussed further. The furnace is housed in a three-storied submerged arc furnace building, with an electrical area building and submerged arc furnace equipments in the ground floor, first floor, second floor and third floor. [0014] The submerged arc furnace building is one single building accommodating a submerged arc furnace, electricals, control room, first floor for monitoring the process happening, circular steel fabricated furnace hood for collecting smoke and dust, and required area in a rectangular shape in all the sides of the furnace. The furnace transformer of 15 MVA with on-load tap changer will be having voltage range of 96 V to 160 V, to operate at 7-8 voltage steps and corresponding currents. The steel fabricated furnace of round shape will be mounted on the bottom of the floor using steel I beams and civil works. The furnace will be lined with high temperature withstanding, high alumina bricks both at the bottom and sides up to the top. [0015] Inside the fire brick lining, high temperature withstanding Soderberg carbon tamping paste will be melted in hot steel trays and rammed into perfection to the required thickness both at the bottom and the sides up to the height of the brick lining. Hence the first floor of the furnace top will be around 4 plus meters from the ground level.

[0016] The entire structure of the furnace building including the furnace area circular clearances, tapping and metal treatment and casting area mostly will be steel fabricated structures with sheet roofing, except the ground floor, first floor and second floor. All structures of this furnace building are fabricated and erected with heavy steel structures.

[0017] Three heavy Soderberg carbon electrodes will be suitably placed to move vertically using a heavy hoist placed on the top of the third-floor steel beams, to lift and lower the electrodes by auto and manual modes. The electrodes may be pre-baked carbon electrodes also. The slipping of the electrodes will be on load and depends upon the consumption of electrodes at the tip.

[0018] On the back side of the furnace top, the furnace transformer will be placed and separated from the first floor with suitable clearances up to a particular height with high temperature withstanding bricks. High quality suitable copper bus ducts capable of carrying up to 50000 amps of required power for the furnace, will run through up to the penetrating point with the projection of the partition wall. From bus ducts suitable water- cooled copper tubes will run to connect 6 copper clamps for each electrode which can be loosened and tightened for slipping purposes. Special provision is provided for this purpose. The copper tubes and copper clamps will be cooled 24/7 using the treated water from the cooling towers. Hence huge tanks for the storage of raw water at ground level, treated water tank in the same line, and another tank as a spare for treated water storage will be attached to the cooling pumping station with adequate cooling spare pumps to run on rotation. Kindly note, the water-cooled copper tubes near the furnace will be connected to the clamps, through flexible copper ducts in which water flows to the inlet and outlet and returns to the cooling towers. Furnace will have daily electrode consumption and hence on-line slipping devices will be installed to enable to lower the electrodes according to the consumption without stopping the plant. All highly modernized smelting furnaces will have this provision to enable a non-stop 24 hrs running. The plant will be stopped only if there is any minor breakdown which the plant people will rectify as soon as possible. The furnace bay as explained above will have a huge crane at 15/20 tons capacity to handle in bay area, up to building length which will go up till the packing and loading section. Kindly note the height of the building is very tall only in the furnace located area. Furnace transformer will also have a suitable crane for maintenance purposes.

[0019] The screened raw materials are weighed according to a computerized batching system and transferred into charging buckets running on monorails. Charging buckets then discharge the premixed raw materials into the furnace every 10-15 minutes through chutes.

[0020] The molten alloy product is drained through one of three tap holes at the bottom of the furnace every 2-2.5 hours into tiltable “teeming ladles” mounted on rail tracks. The teeming ladles are then emptied into large stationary heat resistant cast iron trays or moulds.

[0021] The furnace is a large carbon hearth furnace with 3 electrodes fed with 3- phase alternating current. The voltage supplied to the three electrodes is 3-phase alternating current, typically in the 96-160 V region, with required current. The furnace transformer is supplied from a 110/11 kV substation through 11 kV HT cables. Operating arc currents are typically in the 25-45 kA region, depending on the load. The arc is struck between vertically mounted steel encased consumable Soderberg electrodes and the floor of the carbon hearth. Both the carbon of the self-baking electrodes and its steel casing are consumed in the smelting process, the consumption being 50-60 kg/ton of Fe-Si in the conventional process. [0022] In the conventional process, the following chemical reactions take place to produce ferrosilicon. The reaction below shows reduction of silica by carbon, wherein the silicon combines with the iron to form FeSi or ferrosilicon: SiO ₂ + 2C + Fe = FeSi + 2CO + (atm. oxygen) 2CO ₂ ↑ [0023] The emerging CO from the furnace top combines with atmospheric oxygen and becomes CO ₂ and is then discharged into the atmosphere through the stack and goes for processing in pollution control equipment. SiO ₂ as the fine powder is filtered in the pollution control process equipment and that quantum depends upon the recovery of SiO ₂ in the furnace. Carbon dioxide emission from the furnace not only happens here but also atmospheric oxygen is depleted.

[0024] The same principles as discussed above, apply to the smelting of silicon metal as to ferrosilicon, but it is a much more difficult product to make because there is no iron present to collect the reduced silicon. The carbon control must be more stringently applied because an error of over- or under-coking is more difficult to correct. The analyses of the raw materials, as has been pointed out under the section dealing with this aspect, have much narrower limits and it is particularly important that the silica rock does not unduly break up on heating. Two typical quartzite analyses, shown in Table 1 below are used for this purpose.

Table 1 : Typical Quartzite Analyses for Silicon Metal [0025] First, a large part of the produced silicon metal is used as an alloying element in aluminum to enhance the mechanical properties of cast and wrought aluminum alloys. As iron is a detrimental element in aluminum, the iron content of the silicon for these purposes must be controlled.

[0026] The second important area is the utilization of silicon in the chemical industry to produce silicones and similar derivatives. Silicones can be liquid oil, grease, rubber, and solid resin and are chemically inert, water repellent, and stable up to 400°C. They are used for medical applications, electric insulators, protective coatings, hydraulic fluids, and lubricants. The most important property of the silicon to this group of customers is the content of impurity elements, but the structure and grain/lump size of silicon are also important.

[0027] Finally, as a semiconductor, silicon is widely used as a raw material in the electronic industry. For these applications, purity and dopants control are critical factors and hence the metallurgical grade Si (MG-Si) must be further refined to fulfill its requirements. Although MG-Si usually has silicon content from 98.5% to 99.5% Si, the impurity content in, for example, solar photo-voltaic devices must be in the ppm level and for electronic devices, it must be in the ppb level. The most used refining method for both products is the Siemens process where the raw material silicon is transformed to silicon-chlorine gaseous compounds, which are distilled and then reduced back to pure silicon.

[0028] Some of the drawbacks of the existing technology are the high-power consumption which makes production difficult in areas where cheap power is unavailable. Further, the release of large amounts of CO ₂ accompanying the process is environmentally damaging and increases the cost of compliance with regulations. The invention proposes a novel apparatus and process that provide remediation for problems discussed above.

[0029] While the above are well-known drawbacks of existing technology, anomalous production of Si and Fe has been reported in arc experiments (Monti 2001, Srinivasan 2007). The Si and Fe are believed to be produced by a combination of C and O nuclei via a low energy nuclear reaction (LENR). More specifically, tonnage quantities of ferrosilicon were reported in excess of stoichiometric yield during the operation of ferrosilicon plant (Srinivasan, Transmutations Chapter, Case 10). In this case, C and O being readily available in a ferrosilicon furnace, are thought to have combined to produce the excess ferrosilicon. However, thus far, a clear understanding of these low energy nuclear phenomena has been incomplete or poorly understood. Further, the experimental conditions and apparatus required to consistently produce such low energy nuclear transmutation reactions on an industrially useful scale, has been lacking. It is believed that such transmutations are a result of quantum physical phenomena that are yet to be fully understood. The invention discloses practical device and method to produce ferrosilicon using low energy nuclear transmutation phenomena (LENR).

SUMMARY OF THE INVENTION

[0030] The invention proposes a novel apparatus and process for an environmentally friendly and highly energy efficient process for the production of Fe-Si alloy by LENR process. The apparatus (100) for the production of ferrosilicon, is configured to receive a weight of charge of 80 tons per day comprising SiCL, wood charcoal (Fixed Carbon) and steel scrap in the ratio of 5:2: 1. The apparatus comprises a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D with projected area A of 46.08 m ² and a volume V of 138.24 m ³ . Three carbon electrodes (105-1, 105-2, 105-3) having diameter d ₁ and configured to be raised or lowered are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times d ₁ . An AC power drive is configured to supply a 3 -phase voltage supply ranging between 96-160 V to the three electrodes. The furnace is configured to convert the entire weight of charge including SiC>2, C and Fe completely to ferrosilicon, through a low energy nuclear transmutation reaction (LENR). [0031] The combined cross-sectional area of the electrodes in the apparatus is configured to be l/9th of the projected internal area A of the furnace and each electrode is of diameter d ₁ =l.47456 m. The apparatus may comprise a mechanism to vary the pitch circle diameter from 2.4 to 2.5 times d ₁ . In various embodiments, the apparatus is configured to convert the charge to ferrosilicon with zero emission of CO ₂ .

[0032] A method 200 of operating a furnace for production of ferrosilicon is disclosed, the method comprising the steps of: providing a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D equal to 7.662 m, projected hearth area A of 46.08 m ² , height H of 3m and a volume V of 138.24 m ³ . Three carbon electrodes (105-1, 105-2, 105-3) having diameter d ₁ of 1.47456m, are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times d ₁ . The electrodes are configured to be raised or lowered. In the next step (204), the furnace is preheated for 3-4 days to condition the carbon lining of the furnace and cooled and cleaned thereafter. The next step (206) involves starting the arc on an empty furnace at 96 V and running for a few hours, followed by loading silica, carbon and iron in the ratio 5:2: 1 in 300 /400kg batches (208). The loading into the furnace is carried out with voltage at 96V and increasing power level to 3.981312 MW to stabilize ferrosilicon production. In the next step (210) the voltage is increased in transitional steps of 110.86 V, 124 V, 135.77 V and 146.65 V and loading of charge increased to operate at correspondingly increasing power levels. In a final step 212, the voltage is increased to 156.77V and loading of charge is also increased to operate at full power level of 10.616832 MW to cause conversion of the entire charge to ferrosilicon by a low energy nuclear transmutation reaction without emission of gaseous discharge.

[0033] In some embodiments, the step 204 of preheating is carried out using firewood. In various embodiments, the current density at full power level in step 212 is maintained at 230.4 kW/m ² of hearth area. [0034] A method 300 of operating a furnace for production of metallurgical grade silicon metal using the apparatus 100 is disclosed. The method comprising the steps of: providing in step 302 a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D equal to 7.662 m, projected hearth area A of 46.08 m ² , height H of 3m and a volume V of 138.24 m ³ . Three pre-baked carbon electrodes (105-1, 105-2, 105-3) having diameter d ₁ of 1.47456m, are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times d ₁ . The electrodes are configured to be raised or lowered. In the next step (304), the furnace is preheated for 3-4 days to condition the carbon lining of the furnace and cooled and cleaned thereafter. The next step (306) involves starting the arc on an empty furnace at 98 V and running for a few hours, followed by charging silica and carbon in the ratio 5:2 (308) into the furnace with voltage at 98V and increasing power level to 4.1472 MW to stabilize silicon production. In the next step (310) the voltage is increased in transitional steps of 113.2 V, 126.56 V, 138.57 V and 149.67 V and loading of charge increased to operate at correspondingly increasing power levels. In a final step 312, the voltage is increased to 160 V and loading of charge is also increased to operate at full power level of 11.0592 MW to cause conversion of the entire charge to silicon, by a low energy nuclear transmutation reaction without emission of gaseous discharge.

[0035] In some embodiments, the step 304 of preheating is carried out using firewood. In various embodiments, in step 312, the current density at full power level is maintained at 240 kW/m ² of hearth area.

[0036] This and other aspects are disclosed herein. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The invention has other advantages and features which will be more readily apparent from the following detailed description of the invention and the appended claims, when taken in conjunction with the accompanying drawings, in which:

[0038] FIG. 1A illustrates the plan view and FIG. IB shows a cutaway view of the apparatus for producing ferrosilicon and MG silicon metal according to an embodiment of the present subject matter.

[0039] FIG. 2A illustrates a detailed flow chart for producing ferrosilicon.

[0040] FIG. 2B shows a flow chart of a method for producing ferrosilicon, according to embodiments of the subject matter.

[0041] FIG. 2C illustrates a detailed flow chart for producing MG silicon metal.

[0042] FIG. 2D shows a flow chart of a method for producing MG silicon metal, according to embodiments of the subject matter.

[0043] FIG. 3 shows the ground floor layout of a plant for producing ferrosilicon according to embodiments of the invention.

[0044] FIG. 4 shows the first-floor layout of a plant for producing ferrosilicon according to embodiments of the invention.

[0045] FIG. 5 shows the second-floor layout of the plant.

[0046] FIG. 6 illustrates section BB of FIG. 3, showing details of equipment required for plant.

[0047] FIG. 7 shows the transformer and electrical components of the furnace.

[0048] FIG. 8 shows pollution control equipment.

[0049] Referring to the drawings, like numbers refer to like parts throughout the views. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0050] While the invention has been disclosed with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt to a particular situation or material to the teachings of the invention without departing from its scope.

[0051] Throughout the specification and claims, the following terms take the meanings explicitly associated herein unless the context clearly dictates otherwise. The meaning of "a", "an", and "the" include plural references. The meaning of "in" includes "in" and "on." Referring to the drawings, like numbers indicate like parts throughout the views. Additionally, a reference to the singular includes a reference to the plural unless otherwise stated or inconsistent with the disclosure herein.

[0052] The invention in its various embodiments discloses apparatus and methods for environmentally friendly and highly energy efficient process for the production of Fe-Si alloy by Low Energy Nuclear Reaction (LENR).

[0053] In various embodiments, the invention discloses apparatus 100 including a stationary submerged electric arc furnace for the production of ferrosilicon via a low energy nuclear reaction (LENR) is disclosed with reference to FIG. 1A and IB. The apparatus 100 is configured to receive a weight of charge comprising SiCL, wood charcoal and iron. The iron in various embodiments may be iron or steel scrap. The apparatus comprises a hearth furnace body 101 of cylindrical shape with a bottom 102. The bottom may have a diameter D and projected area A over a height H. In some embodiments, the bottom may have a diameter D of 7.662 m, area A of 46.08 m ² and height H of 3 m. The furnace hearth may enclose a volume V of 138.24 m ³ . The furnace is provided with three carbon electrodes 105-1, 105-2, and 105-3. In some embodiments, the electrodes may be Soderberg electrodes of steel-encased carbon. In alternative embodiments, the electrodes may be pre-baked carbon electrodes. Each electrode (say, 105-1) is configured with a diameter of d ₁ . The electrodes may be equidistantly placed within the furnace 101 with a pitch circle 103 of diameter d2 varying between 2.4-2.5 times d ₁ as illustrated in FIG. 1A. In some embodiments, each electrode may have a diameter that is 1.47456 m. The electrodes may be configured to be raised or lowered during operation. In various embodiments, the capacity of the submerged arc furnace is configured to consume 80 tons of raw materials per day of 24 hours continuous operation.

[0054] The apparatus further comprises an AC 3 -phase power supply configured to provide a variable voltage ranging between 96-160 V to the three electrodes. In various embodiments, the furnace transformer providing the AC power supply may be provided with a number of tappings that are selectable using an on-load tap changer. In some embodiments, the number of tappings provided in the transformer may range from 7-8 voltage steps.

[0055] In some embodiments, apparatus 100 is configured to convert the entire weight of SiC>2 + C + Fe in the charge to ferrosilicon with zero emission of CO ₂ .

[0056] In some embodiments, the combined cross-sectional area of the three electrodes 105-1, 105-2, and 105-3 is configured to be l/9th of the projected internal area A of the furnace. In some embodiments, diameter d ₁ of each electrode is configured to be 1.47456 m. In some embodiments, the apparatus 100 comprises a mechanism to vary the diameter of the pitch circle 103 from 2.4 to 2.5 times d ₁ , i.e. from a circle of diameter 3.5389 to 3.6864 m.

[0057] In various embodiments as described with reference to FIG. IB in cross section, the furnace body 101 may be constructed of heavy steel plate 110, a refractory lining 111 and a carbon lining 112. The steel plate 110 may be of sufficient thickness with proper reinforcement to withstand the load of the furnace internals along with charge. The furnace 100 may be placed on a suitable foundation F. The refractory lining 111 may include suitable refractory such as high alumina brick. The carbon lining 112 may comprise carbon tamping/lining paste on the portion of the furnace bottom 102 and sides up to the top.

[0058] In various embodiments, a method 200 for operating apparatus 100 to produce ferrosilicon is disclosed with reference to FIG. 2B. The method involves providing in step 202, the apparatus 100 having dimensions as already described with reference to FIG. 1A and IB. The furnace hearth is initially constructed with firebrick and a suitable grade of carbon paste to form the carbon lining 112. The method then comprises the step 204 of preparing the furnace hearth by preheating. The preheating may in various embodiments be done using firewood or wooden logs. In some embodiments, the preheating may be carried out for 3-4 days. The preheating operation in step 204 is configured to condition the hearth 112 by strengthening and rendering the lining leak-proof.

[0059] The next step 206 involves starting the arc on an empty furnace at 96 V. The arc is run for a few hours to warm up the furnace prior to charging. Charging is started thereafter in the next step 208, in 300/400 kg batches while maintaining the same voltage of 96 V and current at power load of 3.981312 MW. Then we have to enter into step 210 of first two transitional steps of 110.86 V and corresponding load of 5.308416 MW and voltage of 124 V and corresponding load of 6.63552 MW and proportional currents.

[0060] Balance two transitional steps of step 210 are entered where the voltage of 135.77 V and a power load of 7.962624 MW and voltage of 146.65 V and a power load of 9.289728 MW with corresponding currents. Higher voltage steps are entered seeing the operation condition of the furnace carefully. [0061] In the final step 212, the process involves increasing the voltage to 156.77 V and increasing the loading of charge to operate at the full power level of 10.616832 MW. Operation at full power at this voltage level is configured to cause conversion of the entire charge to ferrosilicon by a LENR reaction. In various embodiments of the method, steps 210 and 212 may involve adjusting the spacing between the electrodes by varying the pitch circle diameter to attain LENR conversion of the charge to ferrosilicon. Since the reaction causes the entire C and O to Si, there is no emission of gaseous CO ₂ discharge from the furnace.

[0062] In various embodiments of the method 200, during steps 208-212, the silica, wood charcoal (fixed carbon) and iron in the charge may be mixed as homogeneously as possible before charging into the furnace. In various embodiments, the charge of silica, wood charcoal (fixed carbon) and iron may be added in 300 or 400 kg quantities in a ratio of 5:2: 1.

[0063] In various embodiments, the current density at the full power level during step 212 is maintained at 230.4 kW/m ² of hearth area. The furnace at this stage is configured to consume 80 tons of charge per day to produce 80 tons of ferrosilicon. In various embodiments of the method, the stabilization of operation at full capacity may be accompanied by a reduction of CO/CO ₂ emissions to zero or near-zero levels.

[0064] In various embodiments, a method 300 of operating a furnace for production of metallurgical grade silicon metal using the apparatus 100 is disclosed. The method comprises the steps of: providing in step 302 a hearth furnace (101) of cylindrical shape with a bottom (102), the bottom having a diameter D equal to 7.662 m, projected hearth area A of 46.08 m ² , height H of 3m and a volume V of 138.24 m ³ . Three pre-baked carbon electrodes (105-1, 105-2, 105-3) having diameter dl of 1.47456m, are provided, wherein the electrodes are equidistantly placed with a pitch circle (103) of diameter d2 varying between 2.4-2.5 times dl. The electrodes are configured to be raised or lowered. In the next step (304), the furnace is preheated for 3-4 days to condition the carbon lining of the furnace and cooled and cleaned thereafter. The next step (306) involves starting the arc on an empty furnace at 98 V and running for a few hours, followed by charging silica and carbon in the ratio 5:2 (308) into the furnace with voltage at 98 V and increasing power level to 4.1472 MW to stabilize silicon metal production. In the next step (310) the voltage is increased in transitional steps of 113.2 V, 126.56 V, 138.57 V and 149.67 V and loading of charge increased to operate at correspondingly increasing power levels. The transitional steps may comprise operating at 5.5296 MW power level at 113.2 V, followed by operating at 6.912 MW power level corresponding to 126.56 V, at 8.2944 MW power level corresponding to 138.57 V, and at 9.6768 MW power level corresponding to 149.67 V.

[0065] In a final step 312, the voltage is increased to 160 V and loading of charge is also increased to operate at full power level of 11.0592 MW to cause conversion of the entire charge to silicon, also known as MG silicon metal, by a low energy nuclear transmutation reaction without emission of gaseous discharge. In some embodiments, the step 304 of preheating is carried out using firewood. In various embodiments, in step 312, the current density at full power level is maintained at 240 kW/m ² of hearth area. The furnace at this stage is configured to consume 70 tons of charge per day to produce 70 tons of MG silicon metal.

[0066] In various embodiments of the method 300, during steps 308-312, the silica, and wood charcoal (fixed carbon) in the charge may be mixed as homogeneously as possible before charging into the furnace in batches of 350 kg. In various embodiments, the charge may have silica, and wood charcoal (fixed carbon) in a ratio of 5:2.

[0067] In various embodiments, in the method 200 or 300, the furnace is tapped every 2-2.5 hours to draw molten ferrosilicon or silicon through tapping holes provided at the bottom of the hearth. In the disclosed process, one each of C and O nuclei combine via a low energy nuclear transmutation reaction to form ferrosilicon or silicon and no discharge of gas takes place.

The reaction may be expressed as: ¹² C + ¹⁶ 0 → ²⁸ Si.

[0068] The invention has multiple advantages as set forth here. Using the claimed equipment and LENR process, the emerging CO from the furnace bottom is converted into silicon inside the furnace itself through nuclear transmutation, and emission of CO ₂ to the atmosphere is eliminated. Hence the recovery of silicon in the product goes up tremendously to more than 2-2.4 times of the regular conventional process and pollution is also eliminated. The pollution control equipment installed will be used only during the starting times till stabilization. Kindly note total power and raw materials consumption per day remains same as in the conventional process. Hence the advantage can be understood.

[0069] Although the detailed description contains many specifics, these should not be construed as limiting the scope of the invention but merely as illustrating different examples and aspects of the invention. It should be appreciated that the scope of the invention includes other embodiments not discussed herein. Various other modifications, changes and variations which will be apparent to those skilled in the art may be made in the arrangement, operation and details of the system and method of the present invention disclosed herein without departing from the spirit and scope of the invention as claimed in the attached claims.

[0070] EXAMPLES

[0071] Example 1: Plant Design

[0072] A plant design implementing the invention is discussed further. FIG 2A and FIG. 2B show flow charts for the production of ferrosilicon and MG silicon metal according to the embodiments presented here. [0073] Power is supplied to the furnace and its auxiliaries through a 110/11 KV power line connection and substation.

[0074] Buildings: Three storied submerged arc furnace building, electrical area building and submerged arc furnace equipments in the ground floor, first floor, second floor, and third floor are constructed as detailed in FIG. 3-7. As illustrated in FIG. 3, A) the Smelting furnace is provided with B) Tapping mouths for metal. The furnace hearth with three electrodes is shown as C, while small rail track (D) with tilting ladle for receiving and carrying the liquid metal on the tracks and pouring in the high-quality receiving ladles all falling under H. Also shown in FIG. 3 are industrial lift E, steel staircase F, entrance area into the ground floor G, and molten metal receiving ladles H. A jaw crusher J is available for breaking carbon paste. Mechanical arrangement K is provided on both sides of the rail tracks with wire ropes for hauling the ladles having frame and wheel arrangements. Mechanical maintenance area M and electrical maintenance area L are also shown. Areas N and O are provided for metal breaking, weighing, packing and other activities.

[0075] The submerged arc furnace building is one single building accommodating submerged arc furnace electricals, control room, first floor for monitoring the process happening, circular steel fabricated furnace hood for collecting smoke and dust if any and required area in a rectangular shape in all the sides of the furnace.

[0076] The furnace is connected with a 15 MVA transformer with on-load tap changer having voltage range of 96 V to 160 V, to operate at various voltage steps and currents. The layout of first floor transformer arrangements is shown in FIG. 4. P is furnace transformer with on-load tap changer, Q is furnace and electrical control room, R is for emergency maintenance and other purposes. S is industrial lift. FIG. 5 shows 2nd floor with three openings for the 3 electrodes going into the furnace.

[0077] FIG. 6 shows section B-B across the building, referenced in FIG. 3. Ground floor bunker AA is shown with rope car bucket AB for transporting raw materials to the bunkers which is in raised level at the second floor. Material storage bunker on 2 ^nd floor top, AC is provided with discharge facilities and electronic weighing system. AD shows monorail at a raised level from the second floor for transporting raw materials from the bunkers, moving on monorail wheels and discharging raw materials into the charging chutes for furnace feeding. AE refers to heavy steel fabricated beams with chequered plates for locating 3 heavy lifting hoists for electrodes and connected by steel ropes to electrodes and slipping devices attached to it. Furnace hood AG, pollution control chimney AH, and furnace hearth Al are also shown.

[0078] The steel fabricated furnace of round shape is mounted on the bottom of the floor using steel I beams and civil works. The furnace is lined with high temperature withstanding, high alumina bricks both at the bottom and sides up to the top.

[0079] Inside the fire brick lining, high temperature withstanding suitable carbon paste is melted in hot steel trays and rammed into perfection to the required thickness both at the bottom and the sides up to the height of the brick lining. The first floor of the furnace top is around 4 plus meters from the ground level.

[0080] Smelting furnace and electrical system are shown in FIG. 7. Furnace hearth area/volume Al and furnace transformer P are shown. Copper flats AJ leading to copper tubes, copper flexibles AK connected to the copper tubes and terminating at the copper clamps AL, are shown connected to the electrodes AM. The copper tubes, copper flexibles AK and copper clamps AL are all water cooled. Electrode slipping device AN, three electrodes C, hoists AO, and heavy steel fabricated beams with chequered plates AP, for locating 3 heavy lifting mechanical or hydraulic hoists for electrodes are shown. Also shown are furnace hood AQ and pollution control chimney AR. Pollution control filter elements are shown in FIG. 8, with 500 kVA exhaust fan U and filter bags with fitting arrangements V.

[0081] The entire structure of the furnace building including the furnace area circular clearances, tapping and metal treatment, casting area are steel fabricated structure except the ground floor, first floor and second floor concreting. All structures of this furnace building are fabricated and erected with heavy steel structures and sheet roofing.

[0082] Three heavy carbon electrodes are suitably placed and are enabled to move vertically upwards till the heavy hoist placed on the top of the third-floor, to lift and lower the electrodes by auto and manual modes, as required. The electrodes may either be self-baking carbon electrodes or pre-baked electrodes. The slipping of the electrodes will be on load and depends upon the consumption of electrodes at the tip.

[0083] On the back side of the furnace top, the furnace transformer is placed behind a separating wall on the first floor with suitable clearances up to a particular height with high temperature withstanding bricks. High quality suitable copper bus ducts capable of carrying up to 50000 amps required power for the furnace are run through up to the penetrating point with the projection of the partition wall. From the bus ducts suitable water-cooled copper tubes are provided to connect 6 copper clamps for each electrode which can be loosened and tightened. Special provision is provided for clamping the copper clamps to the carbon electrodes. The copper tubes and copper clamps are cooled 24/7 using treated water from the cooling towers. Hence huge tanks for the storage of raw water at ground level, treated water tank in the same line and another tank as a spare for treated water storage are attached to the cooling pumping station with adequate cooling spare pumps to run on rotation. The water-cooled copper tubes near the furnace are connected to the clamps, by copper flexibles through which water flows and returns to the cooling towers. Furnace will have daily electrode consumption and hence on-line slipping devices are installed to enable to lower the electrodes according to the consumption without stopping the plant. The plant is required to be stopped only if there is any minor breakdown which the plant people will rectify as soon as possible. The furnace bay as explained above will have a crane at 15/20 tons capacity to handle in bay area up to building length which will go up till the packing and loading section. Kindly note the height of the building is very tall only in the furnace located area. Furnace transformer will also have a suitable crane for maintenance purposes.

[0084] Example 2: Derivation of Numerical Values for the Design

[0085] Consider area of a circle Ac that is equal to the area of a square A _s of arbitrary value equal to 0.0216 m ² . We have derived a value of pi equal to 7t = 3.13966853139 using the analysis of circles and squares. For a circle of area A _c of the same area 0.0216 m ² , the radius is r=0.082944 m, using the derived value of pi. The corresponding diameter is d=0.165888 m. The circumference of this circle C _c =0.520833333 m.

[0086] The side of a square of area A _s =0.0216 m ² is 0.146969384566991 m, the circumference of which is C _s =0.587877538267963 m. C _s >C _c , and C _s /C _c is a constant, whose value is 1.128724873471245. This value can be rewritten as

For easy remembrance,

Can be used for pi (π) value.

[0087] The value of pi (π) introduced here can be split into two parts, a “pi base” or equal to 3.125 x an “excitation constant” = 1.0046939300469393. The inverse of the volume of the furnace 138.24 m ³ is numerically the same as the fine structure constant known in physics from the days of Sommerfeld for more than a century, which is 1/138.24 = 0.0072337962963379. The corrected value for fine structure constant is arrived at now.

This number can again be written as a product of a base and the excitation constant derived before, i.e. 0.0072 x 1.0046939300469393.

If we use the values for the constants ħ, h or π as found in standard tables or books, you will not get the correct answer. Kindly note the correct values of each constant are as follows which is used in our calculation to arrive at the value of 1/138.24= 0.00723379629629629629. The correct values of each constant is as follows, which are required to be used in the equation:

The square root of the fine structure constant 0.00723379629629 is equal to 0.08505172714, the electron coupling constant referred by Richard Feynman (1985, reprinted 2004, Universities Press, ISBN 8173712115, p.129).

[0088] Our observations are that the value of most of the fundamental constants found in standard tables and all other science literature books are having minor errors, which prevents us from arriving at the exact value. For example, the speed of light is 3,00,000,000 m/s and not 2.997924590 x 10 ⁸ m/s as understood and used at present. This will create a final error in the derivations. The error may be due to the error in the very measurement or in the measure of the meter or in both. This has to be pointed out in our submission, since we have introduced amendments to 2 new equations which may lead some readers to disagreement, 1/137 and 1/138.24 is a typical example case. [0089] With reference to the invention, we refer to the words of Feynman “There is a most profound and beautiful question associated with the observed coupling constant, e—the amplitude for a real electron to emit or absorb a real photon. It is a simple number that has been experimentally determined to be close to --0.08542455. (My physicist friends won’t recognize this number, because they like to remember it as the inverse of its square: about 137.03597 with an uncertainty of about 2 in the last decimal place. It has been a mystery ever since it was discovered more than 50 years ago, and all good theoretical physicists put this number up on their wall and worry about it.) [0090] Immediately you would like to know where this number for a coupling comes from: is it related to pi, or perhaps to the base of natural logarithms? Nobody knows. It’s one of the greatest damn mysteries of physics: a magic number that comes to us with no understanding by man. You might say the “hand of God” wrote that number, and “we don’t know how He pushed His pencil.” We know what kind of a dance to do experimentally to measure this number very accurately, but we don’t know what kind of a dance to do on a computer to make this number come out – without putting it in secretly!” The critical number which plays here is 1/138.24 rather than 1/137. [0091] Again By multiplying the same with the value comes 0.0868055555 and by dividing by the same we get value of 83333. Number 0.083333 is the number of electron rest energy x excitation constant and the number 0.0868055555 is exactly 4% higher than the above. Fine structure constant seems to have multiple interpretations for also represents for volume of space and its mass / energy content. 138.24 represent the volume in cubic meters and 1 represents a mass of 1 ton or 1 kg or 1 gram for 138.24 cubic meters. At this stage, we have to handle all the three options till the specific one is identified without mistakes. The volume of space is unimaginable and looks like infinity. But yet to the above understanding even though the volume of space is very large, yet it is finite.

(having the above number) Ascending order of space volume and mass content can be and descending order can be

0.995328 ton of rest mass is existing and with excitation constant it becomes 1. It is reasonable to assume that 96% of the total mass/energy equivalent is in space and only 4% is existing as manifested bodies like planets and stars. Hence the volume of our universe is 1.3824 X 10 ^Υ where the value of Y is unknown. By considering the additional 4% of manifested bodies of 0.041472 in the Universe, total mass-energy in the Universe becomes 1.0368 x excitation constant. The volume as well as energy of space has bearing on the reactions occurring within the ferrosilicon furnace of the invention. [0092] In scientific literature, we find the following details for electron.

An amendment to the above value is necessary to get clear understanding. Electron rest mass is only 9 X 10 ^-31 Kg. It is under the influence of atomic excitation constant which is equal to , hence the value becomes 9 x 1.01192885125= 9.10735966125 X 10 ^-31 Kg. To determine the energy content of rest mass of electron of 9 X l0 ^-31 Kg, we have to understand that during the functioning of the electron, the atomic excitation constant becomes square of it to 1.024. Hence the equation has to be really energy (E)= 9 X 10 ^-31 X C ² X 1.024. Hence the energy content of electron = 8.2944 x 10 ^-14 J or 5.184 x 10 ^-1 MeV, same is the case with respect to proton and neutron. Proton rest mass = 1.65888 X 10 ^-27 Kg and proton rest energy = 1.529923808X 10 ^-10 J or 9.5551488 X 10 ² MeV. The ratio of the mass to proton and neutron compared to electron is 1843.2. Hence, mass energy equation of E= mc ² becomes E= mc ² x 1.024. Having studied the mass and energy level of electron, proton and neutron, let us consider again now, 0.00723379629 which means 7.2 Kg or 7.2 grams or 0.0072 gram of rest mass X excitation constant which is for per cubic meter of space. Energy content of this is E = mc ² X 1.024.

Let us take the middle path of the three options and consider 7.2 grams per cubic meter of space.

E = mc ² x 1.024.

E = (7.2 X 10 ^-3 X 1.00469393004) X (3 X 10 ⁸ ) ² X 1.024

= 7.233796296288 X 9 X 10 ¹⁶ X 1.024

E = 6.6666666 X 10 ¹⁴ J

This seems to be the place of origin of Universal Gravitational constant (G) and its value is 6.6666666. G always existing in living / dynamic state. By dividing the same by excitation constant it becomes 6.63552 which is Planck energy number.

[0093] The inventor has arrived at the invention based on rigorous experimentation with ferrosilicon plant, and has proposed the above explanation and derivation of the dimensions of the furnace for attaining LENR reaction for production of ferrosilicon. Similar calculations have been done to derive the dimensions of the electrodes, the furnace hearth area and height. The steps required to ignite LENR reaction and to obtain complete conversion of the C and O from the reactants into ferrosilicon by LENR in the detailed description has also been arrived at after thorough investigaion. It is believed that the LENR reaction is produced under certain special dimensional and energetic conditions that are related to fundamental properties of space and matter.

The Fundamental Constants

The figure in brackets which follows the final digit, is

Certain physical constants have special importance on the estimated uncertainty in the last digit. account of their universality or place in fundamental

Thus C = 2.997924590(8) x 10 ⁸ ms ^-1 could be written theory. These are given blow, first in SI and then in cgs C = (2.997 924 590 ± 0.000 000 008) x 10 ⁸ ms ^-1 units.