scholarly journals Heat balance analysis in electric arc furnace for process improvement

2020 ◽  
Vol 170 ◽  
pp. 02012
Author(s):  
Sandeep Ohol ◽  
Mathew VK ◽  
Savita Shinde ◽  
G. Balachandran
Keyword(s):  
Heat Balance ◽  
Process Analysis ◽  
Exothermic Reaction ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Process Efficiency ◽  
Balance Model ◽  
Arc Furnace ◽  
Reaction Heat

The current study deals with optimizing the melting process used in electric arc furnace by heat balance equations. Heat balance is a very important aspect in an arc furnace in which the energy input consists of electrical energy [65%], chemical energy [25%] and exothermic reaction heat [10%]. This energy is optimized with the charge mix, charge quantity, fluxes, fuel used, and O2 used in the burners. The present model considers all these aspects and gives heat distribution in the process. The model spreadsheet gives a reasonable prediction in terms of metal yield, composition, and energy consumption. The model also predicts the amount of iron oxidized in the process. The mass and heat balance model is a useful tool for process analysis and improves the process efficiency of electric arc furnace steelmaking.

scholarly journals A Combined Pyro- and Hydrometallurgical Approach to Recycle Pyrolyzed Lithium-Ion Battery Black Mass Part 1: Production of Lithium Concentrates in an Electric Arc Furnace

Metals ◽  
2020 ◽  
Vol 10 (8) ◽  
pp. 1069
Author(s):  
Marcus Sommerfeld ◽  
Claudia Vonderstein ◽  
Christian Dertmann ◽  
Jakub Klimko ◽  
Dušan Oráč ◽  
...  
Keyword(s):  
Raw Materials ◽  
Maximum Yield ◽  
Lithium Ion ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace ◽  
Mineralogical Characterization ◽  
Secondary Sources ◽  
Cobalt Nickel

Due to the increasing demand for battery raw materials such as cobalt, nickel, manganese, and lithium, the extraction of these metals not only from primary, but also from secondary sources like spent lithium-ion batteries (LIBs) is becoming increasingly important. One possible approach for an optimized recovery of valuable metals from spent LIBs is a combined pyro- and hydrometallurgical process. According to the pyrometallurgical process route, in this paper, a suitable slag design for the generation of slag enriched by lithium and mixed cobalt, nickel, and copper alloy as intermediate products in a laboratory electric arc furnace was investigated. Smelting experiments were carried out using pyrolyzed pelletized black mass, copper(II) oxide, and different quartz additions as a flux to investigate the influence on lithium-slagging. With the proposed smelting operation, lithium could be enriched with a maximum yield of 82.4% in the slag, whereas the yield for cobalt, nickel, and copper in the metal alloy was 81.6%, 93.3%, and 90.7% respectively. The slag obtained from the melting process is investigated by chemical and mineralogical characterization techniques. Hydrometallurgical treatment to recover lithium is carried out with the slag and presented in part 2.

Electromechanical Coupled Response of the AC Electric Arc Furnace Structures During the Scrap Melting Process

2012 ◽  
Author(s):  
Eugenio G. M. Brusa ◽  
Nicola Bosso ◽  
Nicolò Zampieri ◽  
Stefano Morsut ◽  
Maurizio Picciotto
Keyword(s):  
Flexible Structures ◽  
Electric Circuit ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Design Parameters ◽  
Vertical Position ◽  
Arc Furnace ◽  
Hydraulic Actuator ◽  
Scrap Melting

Prediction of structural dynamics of the Electric Arc Furnace (EAF) is rather difficult, because of a number of phenomena occurring during the scrap melting process. Three large electrodes, corresponding to each phase of a AC circuit, are lowered by the main mast towards the scrap to activate the melting process, induced by the electric arc. Electric current fed to each electrode produces a strong magnetic field and applies an electromechanical force on the other electrodes. Arc voltage looks irregular upon time, even because of the scrap motion within the vessel and temperature growth. The vertical position of the mast is controlled by an hydraulic actuator. Nevertheless, a heavy vibration of the structures affects the regularity of the melting process. A fully coupled model of the whole system is herein proposed, through a multi-physics approach. A first analytical approach, describing the electric circuit of the whole system, is implemented into a Multi Body Dynamics (MBD) model of the EAF, while a reduced Finite Element Method (FEM) model of the flexible structures is used for a preliminary optimization of the design parameters. Electromechanical forces due to the mutual induction among the electrodes are computed and the dynamic response of the system is investigated. Proposed model allows a first refinement of the EAF design, although a complete experimental validation on the real machine has to be performed, in spite of problems due the extremely difficult accessibility of structures during the melting process.

Process Analysis of the Electric Arc Furnace Melting for Alumina Spinel Production

2012 ◽  
Vol 602-604 ◽  
pp. 2104-2107
Author(s):  
Guo Chao Qi ◽  
Feng Jun Shan ◽  
Qiang Li ◽  
Jing Yuan Yu
Keyword(s):  
Electric Power ◽  
Power Efficiency ◽  
Process Analysis ◽  
Electric Energy ◽  
Power Input ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace ◽  
High Quality ◽  
Furnace Melting

Alumina spinel is widely used as a refractory material in metallurgy industries. Arc furnace melting method is suitable to produce high quality alumina spinel. However, the high melting temperature (> 2200 °C) and high electric energy consumption limit the application of this method. There exists huge opportunity for energy saving through process optimization. A newly designed 2400 kVA electric arc furnace is used as melting facility to produce alumina spinal in this study. It shows from the experiments and analysis that melting voltage has much effect on electric power input and electric efficiency. At voltages higher than 150V, stable electric power input and adequate efficiency can be maintained. Stable melting voltage is difficult to maintain at 100-150V range and power efficiency are also apparently lower. For voltage less than100V, the process is very difficult to control and energy efficiency are very poor. Too high voltage on the other hand can lead the electric arc expose directly to the surroundings and increase the energy loss. In practical melting process, controlling the melting voltage at 140-160V range is suitable for high quality alumina spinel production.

scholarly journals ENERGY EFFICIENT WATER-COOLED ELEMENTS FOR FOUNDRY CLASS ELECTRIC ARC STEELMAKING FURNACES

2021 ◽  
pp. 55-58
Author(s):  
S. Timoshenko ◽  
E. Nemtsev ◽  
M. Gubinski
Keyword(s):  
Energy Efficiency ◽  
Energy Efficient ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
General Purpose ◽  
Electric Arc ◽  
Oxidation Potential ◽  
Low Energy ◽  
Specific Power ◽  
Arc Furnace

Possibility of a wide choice of original charge and variation of oxidation potential in melting process makes the electric arc furnace (EAF) a general-purpose unit in foundries. Energy-intensive classical technology with insufficient specific power of the transformer, irregular operation with forced downtime predetermine a low energy efficiency of foundry class furnaces [1,2]. Flat and shallow bath of the EAF enhances the problem.

Analysis of Stiffening Effect and Rupture in Dynamics of Graphite Electrodes of the Electric Arc Furnace

2014 ◽  
Author(s):  
Eugenio G. M. Brusa
Keyword(s):  
Numerical Model ◽  
Dynamic Behavior ◽  
Position Control ◽  
Melting Process ◽  
Integrated Approach ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Vertical Position ◽  
Arc Furnace ◽  
Stiffening Effect

Prediction of dynamic behavior of electrodes of the Electric Arc Furnace (EAF) fed by AC current is rather difficult because of several phenomena superposed, particularly during the first step of melting process, i.e. the so-called perforation, and in case of melting of metallic scrap. Unexpected ruptures of electrodes are often observed as a consequence of vibration. Dynamic excitation is applied by the vertical position control of the mast supporting the electrodes and by the Lorentz’s forces generated by the magnetic flux provided by each electric phase. Moreover, the irregular distribution of stiffness along the electrode, being due to the sensitivity of material properties upon temperature, affects quite a lot the dynamic response of the structure. To identify the origin of the observed ruptures and to suitably predict the dynamic behavior of the whole system a modeling activity was performed. A numerical model of the EAF structures was built, by resorting to an integrated approach based on the Finite Element Method and on the Multi Body Dynamics, then it was preliminarily validated on an existing plant. It demonstrated that stiffening effect upon the graphite electrode induced by temperature distribution makes dangerous the action of the vertical position control, when it is applied too fast and excites the flexural modes of the electrode. Numerical model allowed refining the design of the electrode and improving the safety factor as well as finding some design requirement to suitably limit the operation of the position control system.

Energy Savings in the Melting Process of an Electric Arc Furnace

2000 ◽  
Vol 33 (13) ◽  
pp. 561-566
Author(s):  
Luís Gomes ◽  
Anikó Costa ◽  
Dirk Tilsner ◽  
Carlos Soares ◽  
Carmen Morgado
Keyword(s):  
Energy Savings ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Arc Furnace

Mechatronic Modeling and Optimization of the Structural Layout of the Electric Arc Furnace

2014 ◽  
Author(s):  
Eugenio G. M. Brusa ◽  
Stefano Morsut
Keyword(s):  
Electromechanical Coupling ◽  
Position Control ◽  
Melting Process ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Clear Correlation ◽  
Vertical Position ◽  
Arc Furnace ◽  
Length Constant ◽  
Multi Body

Vibration of electrodes in Electric Arc Furnace (EAF) fed by AC current for steel melting is usually fairly large. It might be dangerous for the EAF operation and often reduces the efficiency of melting process. Vibration amplitude depends on the vertical position control operated to keep the arc length constant as much as possible and to the electromechanical actions due to the mutual magnetic induction among the three electric phases. Since designer of the EAF system needs a clear correlation between each design parameter and the dynamics observed a first modeling activity was performed. A mechatronic approach was implemented, by including the electromechanical coupling into the structural analysis performed to predict the system dynamics. A Multi Body Dynamics (MBD) code was used in cooperation with the Finite Element Method (FEM). A preliminary experimental validation on a real plant was tentatively performed.

scholarly journals Analysis of Energy Balance for a Steel Electric Arc Furnace

2020 ◽  
Vol 16 ◽  
Keyword(s):  
Energy Efficiency ◽  
Energy Balance ◽  
Heat Recovery ◽  
Process Analysis ◽  
Cooling Water ◽  
Electric Arc Furnace ◽  
Electric Arc ◽  
Exhaust Gas ◽  
Actual Process ◽  
Arc Furnace

A process and energy analysis was performed for an Electric Arc Furnace for steel production in order to determine the energy efficiency defined as losses contribution in the total energy input. Process analysis was performed during operation for one batch, measuring the relevant process parameters. Energy balance revealed that a significant potential for improvement exists, the main directions being reducing the cooling water loss (for example, by implementing a heat recovery system), reducing the loss during loading and adjustment by implementing technology changes and automation and reducing the loss through exhaust gas. Although implementation of heat recovery systems on the cooling water circuit and exhaust gas duct will not influence the actual process energy efficiency, it is expected to improve the overall energy expenditure by integrating other heat consuming equipment.

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