From the experts: Enabling Tailored application setups for XRF on ferroalloys

For many years, X-ray fluorescence (XRF) has been the preferred method for quantitative analysis in the steel industry, known for its consistently reliable and accurate results. However, the analysis of direct reduced iron and ferroalloys, such as ferrosilicon, ferrochromium, and ferromanganese with borate fused beads has been a challenge.

XRF analysis of these materials is more difficult compared to other matrices, and the risks are significant: as the price of ferroalloys depends on their metal content and purity, even a small error can lead to significant price differences or variations in steel quality.

We met with ferroalloy application specialist Mehtap Eyrik to discuss how Malvern Panalytical helps steel and ferroalloy producers overcome these challenges. Read on to learn how Mehtap and her team are helping ensure that XRF delivers the same consistency, reliability, and accuracy for this complex application.

Why ferroalloy elemental analysis is critical

Ferroalloys are produced using specific ores that contain the necessary elements for alloy formation as well as essential additives

Some manufacturers produce their ferroalloys in-house, some buy them – “but accuracy is critical in every scenario,” Mehtap says.

She explains that mining companies can face significant financial losses if even a minor bias is detected in their overall ore analysis procedures. Consequently, their financial success depends heavily on the accuracy of their elemental analysis

For example, elements such as phosphorus and sulfur are considered impurities in ferroalloys due to their potential negative effects on the quality and performance of the final steel products. Therefore, not only is analyzing the major elements important, but accurately analyzing the trace elements is also essential.

The issues with traditional analysis approaches

The traditional method for ferroalloy analysis is wet chemistry, but as Mehtap explains, “it has its downsides: in particular, it requires the use of aggressive acids like sulfuric acid and hydrofluoric acid to dissolve samples.” This additional manual labour, which must be performed by an analyst due to the safety risks of the acids, makes wet chemistry a much slower technique than XRF. This is a major disadvantage in high-throughput applications like steel production.

In contrast to traditional “wet chemistry” methods, the analysis of ferroalloys using XRF spectrometry—typically conducted with pressed pellets or loose powders—faces challenges in accuracy due to significant metallurgical variations and particle size influences. However, these issues can be effectively addressed by analyzing samples as borates fused beads, which significantly improves both accuracy and precision. 

Finding a solution for oxidizing ferroalloy samples

Preparing ferroalloy samples for borate fusion can be quite challenging due to their composition of highly reduced metallic particles. To achieve successful fusion, it is crucial that these samples are fully oxidized. This complete oxidation not only ensures optimal results but also prevents any permanent damage to platinum wares. Mehtap adds ‘’My team specializes in sample preparation methodologies, carefully selecting the appropriate types and quantities of oxidizers. We also develop comprehensive fusion programs tailored to each specific sample type, ensuring consistent and reliable outcomes in our analyses.’’

The key capabilities behind our ferroalloy application setup support…

Our ability to adapt the analytical process for every client’s needs rests on the combination of multiple capabilities. “For example, the FORJ can be a key part of a refined sample preparation procedure, providing fast, accurate, and safe fusion,” Mehtap explains.

Another key ingredient is the capacity to create synthetic standards in our lab in Nottingham, UK. The needs of different industries have grown, and new alloy compositions may appear, while sometimes, commercial standards could be out of stock. In these situations, our custom calibration standards fill the gaps where commercial options are lacking.

‘’The final ingredient is using our team’s expert knowledge while setting up the pre-calibrations at the factory before shipping the system, or during the on-site support we can set up the applications and share our expertise. “We develop tailored XRF applications to meet specific customer requirements. This means adapting our technology to solve the unique challenges they face. Every application setup requires its own process, with specific corrections to achieve accuracy and precision,” Mehtap explains.

She even once spent three weeks on-site support fine-tuning a client’s setup! 

…and how they benefit steel manufacturers

Once the setup is complete, operators can analyze their samples. Steel manufacturers benefit from the ability to analyze both major and minor elements, even at lower levels, such as phosphorus and sulfur. Knowing the presence of these trace elements is also important because they can negatively impact steel quality and reduce its value. By accurately measuring all these elements, manufacturers can make necessary adjustments during production, ensuring high-quality steel that meets customer standards.

Mehtap has completed several such projects – “and clients were always pleased with the result”!

Manufacturers can also choose from a wide variety of Malvern Panalytical XRF instruments depending on their needs and application. For example, the Zetium metals edition is ideal for high throughput thanks to its automated sample handling, enabling operators to run measurements while performing other tasks. Revontium™, an XRF spectrometer, is also a powerful solution for bringing your XRF analysis in-house or elevating your XRF capabilities with ease. 

Thanks to the right fusion bead sample preparation process and application setup, ferroalloy and steel producers can fully leverage the strengths of XRF – achieving greater speed, high accuracy, and crucially, a safer measurement process that doesn’t require a specialized operator.

Find out more about our XRF application services on our website – and if you’d like a more personalized discussion on achieving faster, safer ferroalloy elemental analysis, feel free to contact Mehtap at Mehtap.Eyrik@malvernpanalytical.com