The growing scarcity of conventional oil resources has intensified the focus on shale oil, known for its abundant reserves. Nevertheless, in the process of shale oil retorting, a substantial quantity of harmful waste oil shale residue (OSR) is generated. In this study, OSR and bituminous coal sourced from Fushun City served as the raw materials for the production of Si–Al–Fe alloy in a DC electric arc furnace, proposing a novel way to efficiently utilize OSR. The experiment summarized and analyzed the current oxide reduction theory, combined with the actual experimental results, focused on investigating the phase transformations of OSR during the reduction process. Based on the gaseous suboxide-carbide reaction theory, the reduction mechanism of pellet raw materials at high temperature was proposed. Results showed that the pellet raw materials will first undergo high temperature decomposition during the reduction process, and generated a large amount of carbides. Carbides subsequently reacted with metal suboxides produced in the high-temperature zone of the electric arc furnace to yield alloys. The element distribution of the obtained alloy product was non-uniform, the metallic Si phase was closely adjacent to the SiC substance, and the Fe in the alloy significantly enriched the reduced Al and Ti elements.

Graphical Abstract

中文翻译：

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直流电炉碳热还原油页岩渣（OSR）制备硅铝铁合金

常规石油资源的日益稀缺加剧了人们对储量丰富的页岩油的关注。然而，在页岩油干馏过程中，会产生大量有害的废油页岩残渣（OSR）。本研究以抚顺市的OSR和烟煤为原料，在直流电弧炉中生产Si-Al-Fe合金，提出了一种有效利用OSR的新方法。实验对当前氧化物还原理论进行了总结和分析，结合实际实验结果，重点研究了OSR在还原过程中的相变。基于气态低氧化物-碳化物反应理论，提出了球团原料高温还原机理。结果表明，球团原料在还原过程中首先发生高温分解，生成大量碳化物。随后碳化物与电弧炉高温区产生的金属低氧化物反应生成合金。所得合金产品元素分布不均匀，金属Si相与SiC物质紧密相邻，合金中的Fe显着富集了还原的Al和Ti元素。

图形概要