Ultra-high Power Electric Arc Furnace Introduction
Ultra-high power electric arc furnace mainly changes the arc characteristics of high voltage and long arc to the arc characteristics of high current, low voltage and short arc, so that electric furnace smelting can input higher power and keep the cost of refractory materials within acceptable limits, and shorten the smelting time of each furnace from 4h to less than 2.5h.
Ultra-high Power Electric Arc Furnace Introduction
Ultra-high power electric arc furnace mainly changes the arc characteristics of high voltage and long arc to the arc characteristics of high current, low voltage and short arc, so that electric furnace smelting can input higher power and keep the cost of refractory materials within acceptable limits, and shorten the smelting time of each furnace from 4h to less than 2.5h.
Ultra-high power electric furnace mainly uses electric arc to heat and melt scrap steel.
With the development of ultra-high power electric furnace technology and refining technology outside the furnace, electric furnace production has transitioned from being mainly limited to the field of special steel to the production of all steel grades.
UHP electric arc furnace has the advantages of high efficiency, flexibility, low cost and high quality in a short process.
Main Application of Ultra-high Power Electric Arc Furnace
Used to smelt and produce alloy steel
ordinary carbon steel
and stainless steel
Ultra-high Power Electric Arc Furnace Equipment Features
(1) It adopts the ultra-high power electric furnace external refining-full continuous casting process route.
(2) Most of them are ultra-high power DC electric arc furnaces that are being vigorously developed in various countries around the world. Only Zhangjiagang Runzhong Iron and Steel Company adopts a vertical ultra-high power electric arc furnace (SSF).
(3) The unit power of the transformer is increased from 700kVA/t to 800kVA/t.
(4) The supporting technology of the UHP electric arc furnace is more complete, such as the AC electric arc furnace adopts high impedance power supply technology, direct conductive arm, oxygen combustion nozzle, furnace bottom blowing Ar (or N₂) stirring, and all electric furnaces are equipped with furnace door spray carbon powder and oxygen gun manipulator and spray-type water-cooled electrodes.
(5) The smelting cycle of each furnace is shortened from 90-100min to 58-75min, and the hourly productivity is increased to 80-130t.
Ultra-high Power Electric Arc Furnace Equipment Composition
The furnace body of the ultra-high power electric arc furnace is composed of a furnace cover, a furnace door, a steel tapping trough and a furnace body.
The furnace bottom and furnace walls are built with alkaline refractory materials or acidic refractory materials, short nets, tilting furnace mechanisms, electrode lifting mechanisms, furnace cover lifting and rotating mechanisms, water cooling systems, hydraulic systems, high-voltage systems, electric furnace transformers, low-voltage system automation control systems, etc.
Sanrui Ultra-high Power EAF Steel-Making Technical Advantages
Low Power Consumption and Cost Reduction
The high current system of the Ultra-high power electric furnace uses pure copper as the conductive medium, and the entire loop resistance is small. Taking full account of the skin effect when current passes through conductors, the cross arm adopts a box-shaped copper-steel composite plate structure, which can effectively reduce resistance and heat generation. Reasonable high-current system layout makes various current impedances smaller.
EAF Equipment Operation is More Stable and Smelting is Safer
The entire hydraulic drive is equipped with an accumulator, which stabilizes the pressure of the hydraulic system and makes the equipment run more stably. At the same time, in emergencies such as power outages, the equipment can continue to perform unfinished operations, which improves the safety of smelting.
Electrode Consumption Reduced
The anti-electrode breakage system can effectively reduce the chance of electrode breakage during the smelting process. In particular, avoiding electrode breakage during the scrap melting process is equivalent to saving an entire furnace of molten steel and reducing economic losses.
The Equipment is Simple to Operate and Easy to Use
Electrical automation control adopts human-machine interface, which simulates the form of real furnace body and is easy to operate. Batching, loading, smelting and tapping can all be operated on the computer.
High Arc Starting Efficiency
Using a new type of electrode adjustment system, the electric arc furnace electrode lifting control breaks the previous single signal return control technology and adopts multi-signal collection and PLC signal comparison technology to increase the electrode arc starting speed and avoid long-term effects on the UHP electric arc furnace during the arc starting process. Upper level power grid system.
Diversification of Dust Removal Systems
The dust removal systems we are equipped with are diversified and can be equipped with different forms of dust removal equipment according to the environmental protection requirements of different countries.
Ultra-high Power Electric Arc Furnace Parameters
| Model | Furnace Shell Inner Diameter | Capacity(T) | Transformer Parameters | Electric Reator Capacity | Graphite Electrode Diameter |
| (mm) | (Kvar) | (mm) | |||
| Rated Capacity | |||||
| (MVA) | |||||
| HX-30 | 4600/4800 | 30/45 | 25-32 | 7000 | 450 |
| HX-60 | 5400 | 60/70 | 45-55 | 9000-11000 | 500 |
| HX-70 | 5600 | 70/80 | 55-65 | 11000-13000 | 500 |
| HX-80 | 5800 | 75/85 | 60-70 | 12000-14000 | 500-550 |
| HX-100 | 6200 | 100/120 | 75-85 | 15000-17000 | 550-600 |
| HX-120 | 6400 | 120/140 | 90-110 | 18000-22000 | 600-650 |
| HX-150 | 6800 | 120/170 | 120-130 | 24000-25000 | 650 |
Scope of Ultra-high Power Electric Arc Furnace Supply
Furnace body: furnace shell, furnace door mechanism, tapping spout mechanism
Furnace roof: tubular water-cooled furnace roof, refractory center roof (this is a drawing produced by the seller, made by the buyer)
Furnace croof lifting and rotating mechanism: furnace cover lifting mechanism (cylinder, chain, gear, etc.), (Γ frame), rotating mechanism, rotating locking mechanism
Tilting mechanism: arc-shaped frame, base, tilting hydraulic cylinder
Electrode cross arm and lifting mechanism: electrode support arm, electrode clamping device, lifting mechanism
Short network: stainless steel bracket, compensator, water-cooled cable, stainless steel bracket, water-cooled conductive copper tube
Cooling water system: water inlet distributor, return water tank, pressure gauge, thermometer, valve
Hydraulic system: motor, pump, filter, tank, control valve, accumulator
High-voltage power supply system: isolation switch, voltage transformer, vacuum circuit breaker, current transformer, lightning arrester, etc.
Electric furnace transformer
Low voltage electrical system
Low-voltage power cabinet, PLC cabinet, main operating console, furnace front operating console, hydraulic operating box, control sensor, limit switch, etc.
Automation control system: Siemens PLC
Ultra-high Power Electric Arc Furnace Steelmaking Process
01
Adopt cage-type split furnace shell, which not only enhances rigidity but also reduces weight, and is suitable for the assembly of water-cooled furnace wall and water-cooled furnace cover;
02
Adopt full hydraulic transmission;
03
Improve the secondary side high current conduction system, and a few electric furnaces have adopted direct conductive electrode arms and water-cooled electrodes;
04
Tubular water-cooled furnace wall and water-cooled furnace cover are generally adopted;
05
Eccentric furnace bottom steel-making technology is widely used in steel production electric arc furnace;
06
Some steel production electric arc furnaces are equipped with oxygen combustion nozzles;
07
Furnace door carbon powder spraying facilities and oxygen blowing machinery;
08
Disc-type and spray gun-type furnace replenishment machinery;
09
Furnace cover No. 5 hole and mechanized feeding system for materials in the ladle;
10
The first and second smoke purification systems combined with direct smoke exhaust from the fourth hole of the furnace cover and the fully enclosed cover around the electric furnace;
11
Electric furnace flue gas preheating scrap steel;
12
Computer automatic control is generally adopted;
13
Reactive power static dynamic compensation.
Sanrui Electric Arc Furnace Technology Optimization
After optimizing steel production electric arc furnace technology, Sanrui has achieved the best balance between raw materials, scrap preheating, energy conservation and environmental protection, smelting process control, automation control, smelting cycle and production capacity. The steel production electric arc furnace inputs electric energy into the electric arc steelmaking furnace through graphite electrodes, and uses the arc between the electrode end and the charge as the heat source for steelmaking.
The ultra-high power electric arc furnace uses electric energy as the heat source and can adjust the atmosphere in the furnace, which is extremely beneficial for melting steel types that contain more easily oxidized elements. Utilize high-temperature flue gas from electric furnaces to preheat raw materials through technology and equipment to achieve high efficiency, energy saving, environmental protection and high yield.
With the improvement of UHP electric arc furnace equipment and smelting technology, and the development of the electric power industry, the cost of electric furnace steel making continues to decrease. Nowadays, electric furnaces are not only used to produce alloy steel, but also to produce ordinary carbon steel and iron ore concentrate pellets.
Services Provided by Sanrui
1. Sanrui can provide electric steelmaking solutions, foundation layout and layout drawings
2. Sanrui will send engineers to your factory to install and debug the machine, providing trustworthy after-sales service electric steelmaking solutions.
3. Sanrui provides operation and maintenance personnel training, and the smelting equipment is easy to operate and maintain.
4. Electric steelmaking solutions with competitive price and excellent quality
5. Low investment, high production efficiency and high rate of return
6. Smelting equipment has stable performance and safe production
7. Steelmaking electric arc furnace solutions can be customized according to different needs
8. Production capacity can be adjusted according to customer requirements
9. Environmentally friendly, low energy consumption
Sanrui is well experience in design, manufacturing, installation, commissioning of Ultra-high Power Electric Arc Furnace Steelmaking process equipment.
Sanrui provides steel production electric arc furance engineering, consulting, R&D, design, equipment supply, system integration and software preparation, construction, installation, commissioning, project management, technical services and training, production guidance, operation and maintenance, spare parts supply and other comprehensive engineering and technical services.
Send us your project details and our team of engineers will design a steel production electric arc furance solution based on your needs.
Related Products
Customized metallurgical machinery and equipment range: Electric Arc Furnace, Submerged Arc Furnace, LF Refining Furnace, Vacuum Furnace, Induction Furnace, Dust Remove System, Water Treatment Equipment, etc. Providing the most advanced equipment integration services, metallurgical equipment can be customized according to different needs of customers, and production capacity can be adjusted according to customer requirements.
15-ton electric arc furnace is used for the short-process steelmaking process, using 100% scrap steel or scrap steel + molten iron (pig iron), or scrap steel + sponge iron (DRI) as raw materials for steelmaking.
Electric arc furnaces are used to melt scrap steel for steel production. Electrical energy is used to melt scrap steel. An arc forms between the charged material and the electrode. The heat generated by the arc melts the scrap.
The 5 ton electric arc furnace for steel-making is a special purpose equipment that makes ordinary steel, quality carbon steel, alloy steel and non-corrosive steel with electric arc as heat source and scrap steel (iron) as raw material.
Electric Arc Furnace Steel Making
Electric arc furnace steel making is a steelmaking method that uses the thermal effect of electric arc to heat the charge for melting.
50 Ton Ultra-high Power Electric Arc Furnace
The 50-ton ultra-high power electric arc furnace (50TUPH EAF) adopts ultra-high power, high impedance technology, bottom tapping technology (ETB), furnace wall oxygen oil burner and furnace door carbon-oxygen gun technology.
30 Ton AC Electric Arc Furnace
The 30-ton AC electric arc furnace is used to melt scrap steel to produce steel. Electrical energy is used to melt scrap steel. An arc forms between the charged material and the electrode.
30 Ton electric arc furnace is used for steelmaking short process smelting, using 100% scrap steel or scrap steel + molten iron (pig iron), or scrap steel + sponge iron (DRI) as raw materials for steelmaking.
DC electric arc furnace is an electric arc furnace supplying electric energy with DC power supply. There is only one electrode on the top of the DC arc furnace, which is the negative electrode, and the bottom electrode is the positive electrode.
Our Completed Projects
Sanrui metallurgy furnace equipment integration services are submerged arc furnaces and electric arc furnaces. Sanrui metallurgy furnaces are manufactured using cutting-edge technology to ensure an efficient, high-quality melting process. These furnaces are capable of melting a variety of materials, including steel, iron and alloys, ferroalloys (such as ferrotungsten, high carbon ferromanganese, high carbon ferrosilicon, high carbon ferrochromium, ferronickel alloys) and industrial silicon, calcium carbide, corundum, yellow phosphorus, etc. with precise temperature control and minimal energy consumption. By using Sanrui metallurgy furnace equipments, metallurgical companies can increase productivity and reduce production costs, ultimately increasing profitability.
Sanrui is well experience in design, manufacturing, installation, commissioning of steelmaking furnace process equipment. Send us your project details inquiry and our team of engineers will design a metallurgical furnace equipment system solution from A to Z based on your needs.
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