▪️ The project succeeds in enhancing local manufacturing and reducing energy consumption through an innovative technology for producing ferroalloys
Within the framework of the Ministry of Higher Education and Scientific Research’s commitment to supporting applied research projects that contribute to linking scientific research outputs with industrial needs—considered a fundamental pillar for strengthening the national economy and enhancing the competitiveness of Egyptian industries, particularly in strategic sectors such as metallurgy and energy.
Dr. Ibrahim Ghayyad, Acting President of the Metal Research and Development Center, highlighted the outcomes of the project titled “Production of Ferrosilicon-Magnesium Alloy Using Energy-Efficient Technology.” The project is led by Dr. Mamdouh Mahmoud Issa as the Principal Investigator and is funded by the Science, Technology, and Innovation Funding Authority (STDF). This comes in response to the Authority’s request to spotlight successful research projects with tangible industrial and economic impact.
Dr. Ghayyad noted that the project is being implemented through the Metal Research and Development Center in collaboration with its industrial partner, the Egyptian Ferroalloys Company, representing a distinguished model of integration between scientific research and industrial application.
The research team successfully developed an innovative, energy-efficient, single-stage technology for producing ferrosilicon-magnesium alloy, marking a significant advancement over conventional two-stage production methods.
This technology has achieved a high magnesium recovery rate and resulted in energy savings of approximately 5,000 kWh per ton of alloy produced. It also enables the utilization of waste heat from molten ferrosilicon. A patent titled “An Innovative Process for Producing Ferrosilicon-Magnesium Alloy with High Magnesium Recovery” has been filed and is currently under evaluation, further enhancing the project’s innovative value.
A prototype has been developed, and the alloy was produced on a semi-industrial scale at the Metal Research and Development Center before successfully transitioning to full industrial-scale production at the Egyptian Ferroalloys Company in Edfu. The produced alloy has proven to meet international standard specifications and has already been used in manufacturing ductile iron castings, including pipes, valves, and components for water and wastewater networks.
The project has delivered tangible economic benefits, including reduced energy costs, meeting local market demand for the alloy, and opening new export opportunities—thereby reducing imports and increasing reliance on locally manufactured products.
Accordingly, the project directly contributes to achieving the state’s objectives by localizing the ferroalloy industry, deepening local manufacturing, supporting infrastructure projects, and boosting GDP, in alignment with Egypt Vision 2030 goals in the industrial and energy sectors.
Dr. Mamdouh Mahmoud Issa, the Principal Investigator, stated that the project has also achieved notable scientific progress, with the publication of four international papers in globally indexed journals (Scopus), in addition to one local publication—reflecting the quality and global competitiveness of the research outputs. The project also participated in two prominent international conferences: EGYCAST 2024 and INDEV 2025.
In terms of capacity building, the project supported the completion of a PhD thesis at the Metal Research and Development Center.
It is worth noting that the project is funded by the Science, Technology, and Innovation Funding Authority (STDF) and has relied on an effective collaborative framework involving several entities, including the Metal Research and Development Center, the Egyptian Ferroalloys Company, El Nasr Castings Company, Misr Castings Company, and Al Ahram Engineering Industries & Castings Company. These partnerships have provided a real industrial testing environment, facilitated the transfer of technology from laboratories to production lines, and opened new avenues for investment in the metallurgical industries—particularly in ferroalloy production and foundry feeder industries.
The project’s results have also been promoted through international publications, participation in scientific conferences, and the organization of a workshop to engage with the industrial sector and showcase applied outputs.
In recognition of its outstanding applied impact, the project received the Metal Research and Development Center Award for Best Applied Research Project, reflecting its success as a leading model for transforming scientific research into economic and industrial value.
