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Characteristics of double electrode DC electric arc furnace/ submerged arc furnace

Equipment characteristics: 1.The power consumption is 10%~15% less than that of AC furnace. 2.The consumption of graphite electrode is 40% less than that of AC furnace. 3.Compared with AC furnace, it eliminates the investment of reactive power compensation device. 4.PLC automatic control, production rhythm is stable and reliable. 5.In the smelting process, according to the process requirements, without shutdown, the current remains unchanged, the voltage level increases or decreases at will, and then the arc length changes at will, so as to realize the open arc and submerged arc functions. It can also adjust the voltage and power arbitrarily. 6.The electrode can change its polarity at will in the smelting process, which greatly shortens the smelting time. 7.Because of the serious thermal effect of bottom anode, the bottom of single electrode DC furnace is easy to burn out. The double electrode DC furnace has no bottom anode effect, which completely solves the problem . 8. DC power supply main control board has the function of photoelectric isolation, which can effectively avoid the strong magnetic field in the production site to interfere with the stability of the control circuit in the production process. The board also has the functions of overvoltage, overcurrent and high temperature protection, which can effectively avoid the damage caused by short circuit to the equipment. 9.DC plasma melting equipment electrode center temperature is high, heat concentration, easy to deep buried electrode, furnace bottom is not easy to rise, more suitable for high melting point products smelting. 10.In the smelting process, metal ions in the melt will be concentrated around the negative electrode due to electrolysis, so as to improve the yield and purity of products, which is more conducive to the enrichment of precious metals and other high-value metals. 11.The current direction and electromagnetic field direction of DC furnace remain unchanged. Driven by the magnetic field, the molten slurry circulates in one direction all the time, forming electromagnetic stirring, so that the material melts without dead corners, the product quality is high, and the yield is high. However, the current direction of the AC furnace changes 50 times per second, and the direction of the magnetic field is chaotic, which makes it impossible to realize the electromagnetic stirring function. 12.The noise level is 10~20 dB lower than AC furnace. 13.The graphite electrode consumption of DC furnace is 40% lower than that of AC furnace. 14.The refractory of furnace wall has a long service life. The angle between arc light and graphite electrode of AC furnace is 45 ° and it is easy to hit the furnace wall, thus damaging the refractory of furnace wall. The angle between arc light and graphite electrode of DC furnace is 30 ° and it is not easy to hit the furnace wall . 15.When an accident occurs in the smelting process and a power failure occurs for a period of time, an insulating hard shell will be formed on the surface of the molten liquid. If the single electrode DC furnace encounters this situation, The equipment cannot continue smelting, so it can only be dismantled. Facing this situation, the double electrode DC furnace can start arc smelting again by adding arc striking materials such as coke at the bottom of the electrode.

02

2024-03

Company Profile
ANYANG YOUNENGDE ELECTRIC CO.,LTD is a high-tech enterprise specializing in the research and development, design, manufacture, installation and commissioning of DC plasma melting equipment, high power DC power supply, and solid waste/dangerous waste non-toxic treatment equipment. Our company has obtained 35 new practical technical patents on DC plasma melting equipment. The equipment capacity is from 50kVA to 30000kVA. The process of extracting and enriching rare and precious metals from raw ore, catalyst and industrial solid waste is mature with high yield. The yield of metallic silicon and 75 # ferrosilicon is high in the smelting of silica. The recovery rate of non-ferrous metals is high when waste circuit boards are directly melted. Calcium aluminate smelting process is mature. Our company has carried out professional cooperation and technical exchanges with many enterprises and units at home and abroad, and supplied high-quality products. Product Case List Institute of Mechanics of the Chinese Academy of Sciences (Technical Service Cooperation) Suzhou Institute of Design and Research (Technical Service Cooperation) Anyang Longxin Silicon Industry Co., Ltd (Metallic silicon powder remelting DC furnace) Hubei Boxin New Materials Technology Co., Ltd (Metallic silicon smelting DC furnace) Danjiangkou Huiyuan Hejin Co.,LTD (Metallic silicon smelting DC furnace) Beijing CENTRAL IRON&STEEL RESEARCH INSTITUTE (Steel Furnace) Dalian Wilte Steel Co., Ltd (Vanadium Titanium Iron Experimental DC Furnace) Henan Liyuan Group Co.,LTD ( Ferroalloy Furnace) Wu'an Yuhua Steel Group Co.,LTD (Steel aluminum alloy DC Furnace) Tangshan Ganglu Steel Group Co.,LTD (Steel aluminum alloy DC Furnace) Heilongjiang Jianghui Huanbao Technology Co., Ltd (Ferronickel alloy DC furnace) Guangdong Guangqing Jinshu Technology Co., Ltd (Ferronickel alloy DC furnace) Henan Jiaozuo Mr. Zuo (Multi-function DC furnace) Rizhao Zhenghong Yanchuang New Materials Co.,Ltd (Ferronickel alloy DC furnace) Fujian Anxi Ansheng Mining Co., Ltd (Multi-function DC furnace) Liaoyangshi Taizihequ Boyi Zhuzaochang (Waste zinc slag DC furnace) Chongqing Saiyadi Energy Technology Co., Ltd (Red mud ironmaking DC furnace) Liaoning Fuyun Refractory Co., Ltd (Calcium aluminate DC furnace) Huolinguole GeRun Huanbao Technology Co., Ltd (Calcium aluminate DC furnace) Huolinguole Lifenglvye Co.,Ltd (Calcium aluminate DC furnace) Dalian Yishun Lvse Technology Co., Ltd (Calcium aluminate DC furnace) Danjiangkoushi WanJi Abrasive Materials Co., Ltd (Corundum DC furnace) Jiangsu Nantong TaiYang Technology Co., Ltd (Beryllium copper alloy DC furnace) Jiangsu Nantong TaiYang Technology Co., Ltd (Beryllium copper alloy DC furnace) Indonesia PT METALINDO MAKMUR MANDIRI (Test DC furnace) Korea HF METAL TRADE CO.,LTD (PCB DC furnace) Guangdong Meizhou Mr. Fu (PCB DC furnace) Guizhou Yixiang Kuangye(Group) Zhenyuan Runda Co., Ltd (Precious metals DC furnace) Guangxi Zhongwu Kuangye Co.,LTD (Precious metals DC furnace) Longyan Changyu New Material Technology Co., Ltd (Precious metals DC furnace) Hubei Huanggang Mr. Zhao (Precious metals DC furnace) Henan Yihui Jinshu Technology Co., Ltd (Three way catalytic smelting DC furnace) Shanghai Yudun Xincailiao Technology Co., Ltd (Three way catalytic smelting DC furnace) Zhejiang Qike Shengwu Technology Co., Ltd (Three way catalytic smelting DC furnace) Zhejiang Metallurgical Research Institute (Three way catalytic smelting DC furnace) Hubei Zhongyuan Chucheng Environmental Protection Technology Co., Ltd (Three way catalytic smelting DC furnace) Huaian Zhongshun Environmental Protection Technology Co., Ltd (Two sets of three way catalytic smelting DC furnace) Minshan Huanneng Hi-tech Gufen Co.,Ltd (Lead zinc ore test DC furnace) Zhejiang Teli Renewable Resources Co., Ltd (Copper sludge recovery DC furnace) Keyuan environmental equipment Co., Ltd (Hazardous waste disposal DC furnace) Guanyinshan Waste Incineration Station (Ash harmless disposal DC furnace) Chaozhou Dongsheng Environmental Protection Technology Co., LTD (Rock wool DC furnace) Yongxing Changlong environmental protection Technology Co., LTD (Tin slag smelting and recycling DC furnace) Kunming Dingbang Technology Co., LTD (Tin smelting DC furnace)

Process Description of Medium And Low Carbon Ferromanganese Production by DC Refining Electric Arc Furnace

The relatively mature process for producing medium and low carbon ferromanganese is the electrosilicothermal method. The production of medium and low carbon ferromanganese by electro silicothermal method is achieved by reducing manganese ore with manganese silicon alloy in a DC refining electric furnace, which is currently the main method for smelting medium and low carbon ferromanganese. The carbon content of the medium and low carbon ferromanganese produced depends on the carbon content of the manganese silicon alloy, with very little carbon entering the alloy from the electrodes and raw materials. Due to the different states of furnace materials, they are divided into two forms: hot charging and cold charging. The hot charging method is as follows: the silicon manganese iron produced in the previous workshop does not need to be cast, but can be directly transported to the refining workshop of this project using a tractor, and then poured into the refining electric furnace using a crane to start producing medium and low carbon manganese iron. The cold charging method is to crush the finished block shaped silicon manganese products that have been cast, add them to the refining electric furnace of this project, melt them first, and then smelt them. If the owner has already built a manganese silicon electric furnace, it is recommended to produce it using hot charging method. The electricity consumption for smelting medium and low carbon manganese iron products is less than 580kWh/t; If there is no manganese silicon electric furnace, cold charging can only be used, and the power consumption of medium carbon manganese iron products is about 1800kWh/t. Both production methods use electric silicon thermal refining electric furnaces. Refining electric furnaces are intermittent production, and the smelting process is divided into several stages: remelting, arc ignition, feeding, melting, refining, and tapping. Based on the advanced experience in domestic smelting of medium and low carbon ferromanganese, this project adopts two 6300KVA refining furnaces, with a daily output of 55-60 tons for a single electric furnace and 110-120 tons for two electric furnaces; The annual production of two electric furnaces exceeds 36000 tons, which matches the annual production of 36000 tons of manganese silicon project.

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2024-03

Introduction to Tungsten Iron Smelting in DC Submerged Arc Furnace
The production of tungsten iron using the iron extraction method usually takes 8 hours per furnace, and the furnace type is an open type electric furnace, because special iron spoons are needed to remove molten iron from the furnace. Firstly, add steel shavings and used waste spoons to the furnace and melt them with electricity. Then add tungsten concentrate and reducing agent. Additives should be added multiple times and in small quantities. Take a sample for testing after about 4 hours, and start taking iron after passing the test. When extracting iron, use a dedicated iron digger to extract tungsten iron from the furnace. After removing some of the molten iron, continue to add materials for smelting. Do not take too much iron each time to avoid furnace leakage. Stop feeding before the end of iron extraction. Then enter the next stage of impoverishment. The impoverishment period requires the use of coke and ferrosilicon to reduce WO3 in the slag and improve the recovery rate of tungsten. Subsequently, the slag is discharged and enters the next cycle. The process of producing ferrotungsten using the block method is relatively simple. The furnace body is in a detachable form, with a structure similar to that of a furnace for producing fused magnesia sand. Tungsten concentrate and reducing agent are added together to the furnace, and the generated tungsten iron deposits into a block in the furnace. Then, the power is cut off and the furnace body is cooled. Then, the furnace body is disassembled and the tungsten iron ingots are taken out.
13

2024-03

The influencing factors of silicon thermal reduction method for smelting rare earth ferrosilicon alloy in DC electric arc furnace
For the production of rare earth ferrosilicon alloy by DC electric arc furnace silicothermal method, years of scientific research and production practice have proven that the alkalinity of ingredients, slag to agent ratio, temperature, and stirring strength have a decisive impact on the grade and yield of rare earth alloy. The alkalinity of ingredients, slag to agent ratio, reduction temperature, and stirring strength are commonly referred to as the four elements in the smelting process of rare earth ferrosilicon alloys. 1. Alkalinity of ingredients Rare earth minerals such as fluorocarbon cerium and monazite are transformed into spinel and cerium calcium silicate during the production of rare earth rich slag. Only by reacting with lime at high temperatures (1240-1300 ℃) can rare earth oxides be free in the form of cerium spinel and reduced by silicon or calcium silicate. So lime is the key to promoting the decomposition of rare earth minerals. After adding the reducing agent ferrosilicon, cerium spinel is reduced to rare earth silicides, and lime reacts with the reaction product silica to form dicalcium silicate, tricalcium silicate, etc., reducing the activity of silica and promoting rare earth reduction. However, excessive alkalinity reduces the concentration of rare earth elements in the slag, while also making the slag sticky, affecting the diffusion of reactants and hindering the progress of reduction reactions. 2. Slag to agent ratio The ratio of rare earth rich slag in a DC electric arc furnace to the mass of silicon iron used is called the slag agent ratio. The slag to agent ratio is an important data in ingredient calculation. The experiment conducted by the Shanghai Institute of Metallurgy shows that under the same operating conditions with a selected ingredient alkalinity of 4.0 and a temperature of 1200-1300 ℃, smelting low-grade alloys yields high rare earth elements, while smelting high-grade alloys yields low rare earth elements. 3. Reduction temperature Silicon thermal reduction method is used to prepare rare earth silicon iron alloy. When the reduction temperature is high, the alkalinity of the slag is low, which is conducive to the diffusion of reaction ions, so the rare earth content in the alloy reaches its peak quickly. However, if the temperature is too high, the oxidation rate of the alloy accelerates, making it difficult to control the alloy composition during the smelting process. The oxidized rare earths in the alloy return to the slag, causing a decrease in the alloy grade. It is generally believed that the most suitable reduction temperature is 1300~1350 ℃. If the reduction temperature is raised to 1400-1450 ℃, there is a tendency for the rare earth content in the secondary slag to increase and the rare earth recovery rate to decrease. 4. Mixing intensity The reaction between rare earth slag and liquid ferrosilicon belongs to liquid-liquid reaction, and the diffusion of reactants is a limiting factor in the reaction rate. The liquid-liquid reaction can only be carried out at the interface, and stirring can make the reducing agent ferrosilicon fully contact with the reduced material rare earth slag, expand the contact surface, increase the collision of reactants and the opportunity for products to leave, strengthen the reaction, and reduce smelting time.
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2024-03

One-step carbon thermal reduction method for smelting rare earth silicide alloys in DC submerged arc furnace
In the process of smelting rare earth intermediate alloys in a DC submerged arc furnace, the quality of the furnace material includes its chemical composition, physical and mechanical properties, particle size composition, which plays an important role in the furnace condition, electrical energy consumption, and product quality. The new process of one-step carbon thermal reduction for smelting rare earth silicide alloys is carried out in a 4150kVA DC submerged arc furnace. 1. Raw materials (1) Rare earth raw materials: The rare earth raw materials used in this process are fluorocarbon cerium type rare earth concentrates, with the main chemical components being: ReO>5% BaO<8%. The particle size of rare earth concentrate is generally less than 0.5mm for gravity ore and 200 mesh for flotation ore. From the performance of pelletizing, flotation ore is better. (2) Silicon stone: In principle, the silicon stone used in the smelting of ferrosilicon alloys can be used as the silicon containing raw material for this process, with SiO2>98%, Al2O3<0.5%, and P2O5<0.02%. The block size of silica is 25-80mm. (3) Carbon reducing agent: Various types of coke (such as metallurgical coke, coal coke, petroleum coke, etc.), charcoal, wood blocks, etc. can be used as carbon reducing agents for this process. Considering the needs of the smelting process, it is necessary to use carbon reducing agents with good reactivity and high specific resistance, while also considering production costs. In actual production, it is often used in combination. ① Coke: Metallurgical coke has a high fixed carbon content, high coke block strength, and low volatile content, but its reactivity is not as good as gas coke, and its specific resistance is low. This process prioritizes the selection of coke particles under the sieve, with a particle size of 1-25mm, of which 3-8mm accounts for more than half. The fixed carbon content is greater than 80%. Gas coke is actually a type of semi coke with good reactivity, high specific resistance, but relatively high volatile content. The fixed carbon content is generally around 78% and the strength is relatively low, but it is not affected when used in a DC submerged arc furnace. ② Charcoal and wooden blocks: The use of charcoal is mainly to adjust the permeability of the furnace charge. Use hardwood charcoal with a block size of 3-50mm, and the quantity of less than 10mm should not exceed 20%. The wooden blocks are made from wood processing plant scraps or dry branches, preferably hardwood. The block size is 20-60mm, and the fixed carbon content is generally>26%. 2. Technological process The main advantages of carbon thermal reduction method are that it can be directly reduced in one step, the reducing agent is cheap, the energy utilization is reasonable, and it can be continuously produced in large quantities. The silicon thermal reduction method has a fast reaction rate, and the product is easy to adjust and control, making it suitable for small-scale production of multiple varieties. When the carbon thermal method achieves error free operation, the rare earth recovery rate is above 90%. The silicon thermal method has added a secondary recovery process, and its recovery rate can only reach 80%. The production of rare earth intermediate alloys by silicon thermal method consumes more than 30% of the corresponding raw materials and electrical energy compared to the carbon thermal method.
12

2024-03

Introduction to the process of smelting high carbon ferrochrome in a DC submerged arc furnace
Chromium iron is divided into high carbon chromium iron, medium carbon chromium iron, low carbon chromium iron, and micro carbon chromium iron according to their carbon content. The carbon content of high carbon ferrochrome is 4-8%, the carbon content of medium carbon ferrochrome is 0.4%, the carbon content of low-carbon ferrochrome is 0.15-0.50%, and the carbon content of low-carbon ferrochrome is 0.06% Chromium iron is mainly used as an important alloy additive in steelmaking, which was previously added in the later stage of steelmaking refining. Now, the focus of chromium iron production is on refining carbon chromium iron. The main uses of high carbon ferrochrome include: (1) Used as an alloying agent for ball steel, tool steel, and high-speed steel with high carbon content, to improve the hardenability of steel, increase its wear resistance and hardness; (2) Used as an additive for cast iron to improve its wear resistance and hardness, while also giving it good heat resistance; (3) Used as a chromium containing raw material for the production of silicon chromium alloys and medium, low, and micro carbon ferrochrome using slag free method; (4) Used as a chromium containing raw material for electrolytic production of metallic chromium; (5) Used as a raw material for oxygen blowing smelting of stainless steel. The smelting methods of high carbon ferrochrome include blast furnace method, electric furnace method, plasma furnace method, etc. The use of blast furnaces can only produce special pig iron with a chromium content of about 30%. At present, high carbon ferrochrome with high chromium content is mostly smelted using the electric furnace method in a DC submerged arc furnace. The basic principle of electric furnace smelting high carbon ferrochrome is to reduce chromium and iron oxides in chromium ore with carbon. The starting temperature for carbon reduction of chromium oxide to produce Cr2C2 is 1373K, the starting temperature for the reaction of producing Cr7C3 is 1403K, and the starting temperature for the reaction of reducing to produce chromium is 1523K. Therefore, during carbon reduction of chromium ore, chromium carbides are obtained, not metallic chromium. The carbon content in ferrochrome depends on the reaction temperature. It is easier to generate carbides with high carbon content than carbides with low carbon content. The raw materials for smelting high carbon ferrochrome include chromium ore, coke, and silica. In chromium ore, Cr2O3 ≥ 40%, Cr2O3/∑ FeO ≥ 2.5, S<0.05%, P<0.7%, MgO and Al2O3 content should not be too high, with a particle size of 10-70mm. Coke requires a fixed carbon content of no less than 84%, an ash content of less than 15%, S<0.6%, and a particle size of 3-20mm. Silicone requires a content of SiO2 ≥ 97%, Al2O3 ≤ 1.0%, good thermal stability, no soil, and a particle size of 20-80mm.