Effects of Raw Material Contaminants on the Ferrosilicon Melting Process in the Submerged Arc Furnace

Machulec, B.; Bialik, W.

doi:10.4028/www.scientific.net/ssp.212.183

Cited by 10 publications

(16 citation statements)

References 2 publications

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“…The physico-chemical model [8] and industrial data [9] show that for a proper FeSi75 smelting process, the energy consumption indicator E should not exceed 8 MWh/Mg. By transforming (6), a formula similar to the statistical formula (3) can be obtained:…”

Section: Relation Between the Furnace Active Power Load And Electric ...mentioning

confidence: 99%

“…In extreme cases, the electrical arc may disappear due to too deep or too shallow position of electrode tips. The presence of the electric arc as a high temperature heat source is necessary to conduct highly endothermic reactions that take place in the arc gas chambers located near the electrode tips [8]:…”

Section: Introductionmentioning

confidence: 99%

“…The electrode position has also an impact on the temperature of the upper zones of the furnace where the condensation reaction of the gaseous SiO oxide takes place [8]:…”

Section: Introductionmentioning

confidence: 99%

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Archives of Metallurgy and Materials

Machulec¹,

Bialik²,

Gil³

2019

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Higher active power of a submerged arc furnace is commonly believed to increase its capacity in the process of ferrosilicon smelting. This is a true statement but only to a limited extent. For a given electrode diameter d, there is a certain limit value of the submerged arc furnace active power. When this value is exceeded, the furnace capacity in the process of ferrosilicon smelting does not increase but the energy loss is higher and the technical and economic indicators become worse. Maximum output regarding the reaction zone volumes is one of parameters that characterize similarities of furnaces with various geometrical parameters. It is proportional to d 3 and does not depend on the furnace size. The results of statistical analysis of the ferrosilicon smelting process in the 20 MVA furnace have been presented. In addition to basic electrical parameters, such as active power and electrical load of the electrodes, factors contributing to higher resistance of the furnace bath and resulting lower reactive power P x demonstrate the most significant effect on the electrothermal process of ferrosilicon smelting. These parameters reflect metallurgical conditions of ferrosilicon smelting, such as the reducer fraction, position of the electrodes and temperature conditions of the reaction zones.

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Section: Relation Between the Furnace Active Power Load And Electric ...mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Archives of Metallurgy and Materials

Machulec¹,

Bialik²,

Gil³

2019

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“…Between the reactors and the environment, as well as between the reactors inside the system, a periodical exchange of mass occurs at the time when the equilibrium state is reached in the reactors. In each cycle, a reaction mixture with the molar composition corresponding approximately to the batch mixture of raw materials for the process is fed into the upper reactor [5]. At the same time, the condensed products of chemical reactions move from the top to the bottom, and the gas phase components move in the opposite direction.…”

Section: Model Of the Fesial Melting Processmentioning

confidence: 99%

Archives of Metallurgy and Materials

Machulec¹,

Bialik²,

Gil³

2018

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An economical alternative for the steel industry which uses a separate ferrosilicon and aluminum for the deoxidization of steel is a complex deoxidizer in the form of FeSiAl alloys. The effectiveness of complex deoxidizers is higher and they have a positive effect on quality improvement and also for mechanical properties of the finished steel. It is associated with a smaller number of non-metallic inclusions and a more favorable its distribution in the structure of steel. Noteworthy are the waste from the mining industry simultaneously contains SiO 2 and Al 2 O 3 oxides with a few of dopants in the form of CaO, MgO, FeO, TiO 2 oxides. These wastes are present in large quantities and can be a cheap raw material for obtaining complex FeSiAl ferroalloys by an electrothermal method. "Poor" hard coal grades which so far did not apply as a reducing agent in the ferroalloy industry because of the high ash content can also be a raw material for the electrothermal FeSiAl process. The electrothermal FeSiAl melting process is similar to the ferrosilicon process in the submerged arc furnace. For this reason, a model based on Gibbs' free enthalpy minimization algorithm was used to analyze the simultaneous reduction of SiO 2 and Al 2 O 3 oxides, which was originally elaborated for the ferrosilicon smelting process. This is a system of two closed reactors: the upper one with the lower temperature and the lower one with the higher temperature. Between the reaction system and the environment, and between the reactors inside the system, there is a cyclical mass transfer in moments when the state of equilibrium is reached in the reactors. Based on the model, the basic parameters of the electrothermal reduction process of SiO 2 and Al 2 O 3 oxides were determined and a comparative analysis was made towards the ferrosilicon process.

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“…Ferrosilicon smelting is a continuous process carried out in the submerged arc furnaces with the Søderberg self-baking electrodes [1][2][3]. Respectively granulated raw materials are charged into the furnace from the top, in the form of the mixture batch consisting: • quartzite, • carbon reducers -coal, coke and wood chips, • carriers of iron -mill scale or iron chips.…”

Section: Introductionmentioning

confidence: 99%

Importance of Electrodes Slipping Algorithm for the Ferrosilicon Smelting Process

Machulec

Bialik

2016

SSP

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The electric arc is one of the most unstable parts of the electrical circuit of submerged-arc furnaces in the ferrosilicon smelting process. In the carbothermal silica reduction electric arc has an important role as a high temperature heat source, and its presence is essential for the proper ferrosilicon process flow. Presence of the of electric arc and temperature conditions of the ferrosilicon process have a direct relationship with position of the electrodes tip and electrodes slipping. In the ferroalloy industry position of electrodes tip as similar as metallurgical parameters of the process are not directly measured. Most often these assessments are still based to a large extent on intuition and experience operating staff of the furnaces, and have qualitative and subjective character. In order to check the existing algorithm of electrodes slipping was carried out statistical studies of the FeSi75 ferrosilicon smelting process. The study was conducted at discrete intervals ∆t = 8h using data recorded by the furnace computer measuring system and methods of statistical data processing. It was found that the size of the electrodes slipping, and Cfix ratio in the feed are correlated and are among the most important parameters which have an impact on the technical and economic indicators of the process.

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Effects of Raw Material Contaminants on the Ferrosilicon Melting Process in the Submerged Arc Furnace

Cited by 10 publications

References 2 publications

Archives of Metallurgy and Materials

Archives of Metallurgy and Materials

Archives of Metallurgy and Materials

Importance of Electrodes Slipping Algorithm for the Ferrosilicon Smelting Process

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