A novel direct-current electric arc furnace (DC-EAF) was designed and constructed in this study for experimentally investigating high-titanium slag smelting, with an emphasis on addressing the issues of incomplete separation of metal and slag as well as poor insulation effects. The mechanical components (crucible, electrode, furnace lining, etc.) were designed and developed, and an embedded crucible design was adopted to promote metal-slag separation. The lining and bottom thicknesses of the furnace were determined via calculation using the heat balance equations, which improved the thermal insulation. To monitor the DC-EAF electrical parameters, suitable software was developed. For evaluating the performance of the furnace, a series of tests were run to determine the optimal coke addition under the conditions of constant temperature (1607 °C) and melting time (90 min). The results demonstrated that for 12 kg of titanium-containing metallized pellets, 4% coke was the most effective for enrichment of TiO2 in the high-titanium slag, with the TiO2 content reaching 93.34%. Moreover, the DC-EAF met the design requirements pertaining to lining thickness and facilitated metal-slag separation, showing satisfactory performance during experiments.
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