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Experiences in Operation of Various Electric-Arc Furnaces Under Experiences in operation of various electric-arcfurnaces under resistance control A. L. Moolman, M. S. Rennie,P. Brereton-Stiles. Mintek, P/Bag X3015, Randburg, 2125, South Africa, Tel. +27 11 709-4111 ABSTRACT advanced power control algorithm by compensating for imbalanced loads Mintek has been involved in research and through the out-of-step (differential) development on submerged-arc furnaces operation of the furnace transformers. for more than 30 years. During this time Implementations on inherently unstable Mintek has studied various aspects of operations, typically the production of ferro-alloy production including the ferro-chrome with a high percentage of operation of DC-Arc furnaces, process fines present in the feed, have resulted in a metallurgy 'and the optimisation of dramatic improvement in production and submerged-arc furnaces. utilisation of available energy. To this day the submerged-arc furnace Mintek has also extended the concept of remains the predominant vessel used in resistance control to other applications ferro-alloy production. Through close besides the production of ferro-alloys. collaboration with the ferro-alloy industry world-wide, Mintek has applied its This paper will examme Mintek's patented resistance control system experience in optimising various processes (Minstral) to over 50 submerged-arc using resistance and power control. furnaces producing a wide range of ferro­ alloys. 1. INTRODUCTION The concept of resistance control has lead The majority of ferroalloys are still to a total paradigm shift in the control of produced in three-phase submerged-arc ferro-alloy furnaces from traditional furnaces. The reasons are that the high current and impedance control, and temperatures and reducing conditions derivations thereof. The correct resistance required are not easily created by other setpoint plays an important role in means. For economic reasons, larger optimising furnace performance. This is furnaces, with bigger electrodes and especially important in silicon and transformers have been built. These ferrosilicon production, where the C3 furnaces have longer time constants, lower factor played an important role in setting power factors and are generally much current set points. more difficult to operate and control than their smaller cousins. Maintaining power Mintek has studied a number of processes input and electrode penetration on these in order to establish criteria for selecting large furnaces is not a simple task that the an optimum resistance. Each process has operator can do efficiently with the a certain range of typical resistances in traditional measurements of current, which it operates. The optimal resistance voltage and power. for each operation depends on a number of factors, predominantly the size and 2. RESISTANCE BASED CONTROL composition of raw materials, feed recipe, and any pre-processing (pellitization, pre­ Mintek developed and commercialised a reduction) performed on the raw materials. resistance controller based on primary electrical measurements to solve some of Power control has become an increasingly the problems of maintaining electrode important aspect of furnace optimisation. penetration based on current control or Mintek has developed and implemented an voltage measurements. This controller has 103 been used on a number of different sized 3. THE DESIGN AND OPERATION furnaces and processes. The question that OFFERROALLOYFURNACES always arises is what the optimal 1 resistance for a specific furnace and Many years ago F. V. Andrea developed process is. The answer depends on a the idea that the electrode periphery number of factors - the type of process, resistance was a constant for each different furnace size, electrode diameter, type and ferroalloy process. W.M. Kelly2 called it size of the raw materials - and usually the "k" factor and presented a set of curves needs to be determined for each individual of the "k" factor versus electrode power operation. density, which were typical of the operation at that time. Andrea further When one looks at the operating developed the concept that the heat that resistances at different power levels of could be dissipated from the surface of a different processes, one sees some very graphite electrode would limit the current distinct trends. Resistance was plotted carrying capacity. Thus we have two against power for 26 different relationships that are as applicable today ferrochrome, ferromanganese-silicide and as they were then: ferrosilicon operations. It was found that for ferrochrome production, there were R oc 1/D two distinct modes of operation. Linear 312 regression equations were calculated for I oc D each process and the results are given in 2 Table 1 and plotted in Figure 1. The R For Soderberg electrodes, the maximum value (as defined in Excel) is a measure of operating current is approximately: the variance of the prediction. There are no R2 values less than 0.7, showing I= 55D312 reasonable linearity. where I is in kA and D is in meters. By Process Resistance equation selecting a reference resistance point, one FeCr +fines -0.042MW + 3.8 0.72 can calculate resistances and powers for a FeCr -0.021MW + 2.0 0.70 range of electrode diameters. FeSi -0 .024MW + 1.7 0.85 3 FeMnSi -0.015MW + 1.2 0.71 J. Westley also looked at the operation of Table 1. Linear resistance predictions large number furnaces, in particular silicon and ferrosilicon furnaces. He found that good operation corresponded to the relationship: R vs MN for FeCr, FeMnSi, FeSi 213 I= C3 P 3.5 E ..c: 3 0 - where I is in kA and P is in MW. One can 2.5 - E -- use !his relationship to plot resistance ai 2 (..) - against power and compare these different c: Ill 1.5 predictions with the regression line for .... .. .!!! ferrosilicon production derived from the I/) Q) 0.5 operational data. 0::: 0 0 10 20 30 40 Table 2 gives the calculated linear regression equations for the data plotted in Furnace power, MW Figure 2. Although neither the C3 nor the - Linear (FeMnSi) -- Linear (FeCr) theoretical relationships are linear, the -- Linear (FeCr (no fines)) - - · Linear (FeSi) linear regression line differs little from the Figure 1. Typical resistance operation prediction over the range of operation. 10· Process FeSi Resistance equation R2 in seconds, leading to control problems as Theoretical -0.025MW + 3.8 0.96 will be discussed subsequently. C 3 -0.016MW + 1.5 0.97 furnaces require high Table 2. Linear predictions for FeSi Ferrosilicon intensity arcs to reach the temperatures required for silicon production. As a R vs MW for FeSI production result, the electrodes are positioned close to the metal bath and small changes in tip 1.4 position can result in large changes in 1.3 resistance. But that is not really the E 1.2 • the porosity of the ..c: problem. Maintaining 0 1.1 within the E bed and the carbon balance ci 1 furnace is much more difficult. Short and 0.9 long term changes in resistivity and electrode penetration result from the crater 0.8 15 20 25 30 35 40 around each electrode growing and collapsing, silicon monoxide jets tunneling Furnace power, MW through the burden, and slag or silicon • R C3 • R theo carbide fluctuations. The interaction effect - - - ·Linear (R CJ) - - Linear (R theo) --Linear (R-FeSi) compounds the problems that these fluctuations present for conventional Figure 2. Actual and predicted FeSi current controllers, and results in resistances excessive electrode movement. Even resistance controllers need some Any of these regression lines could be constraints on their movement. used to specify the transformers for ferrosilicon production at a required power Because of the low vapour pressure of level. The actual operating resistance manganese, ferromanganese production depends very much on the type and sizing requires minimal arcing. Thus almost all of the reductant. Charcoal, coke and coal the conduction is through the low will all have different operating resistivity slag resulting in the low characteristics. The choice of reductant is operating resistances shown in figure 1. usually determined by availability and Since the interaction between the electrode price. currents increases as the power factor decreases (and the power factor is less 4. OPERATING RESISTANCES than 0.7 on all these furnaces), resistance control is essential on most manganese The operating resistance graphs clearly furnaces. But resistance control alone will show that there are distinct operating not solve the penetration problem. modes for each type of process. These Ferromanganse-silicide needs a coke bed modes vary from totally resistive to maintain the silicon grade. This bed conduction to total arcing. Investigations 4 grows and decreases along with the carbon on a ferrochromium furnace using lumpy balance and will change the electrode ores and briquettes showed that 15 to 30% penetration. Arcing can and does occur of the resistance was generated in the arc sometimes and this will also affect the zone immediately beneath the electrode. penetration. Economic considerations have necessitated the use of increased quantities 5. MAINTAINING ELECTRODE of fine chromite ore. This has had a PENETRATION AND POWER INPUT destabilising and cooling effect on the arc producing the very high resistances that Ferrochromium production provides a are common today. Unfortunately, classic example of the problems individual electrodes can switch from a experienced on large high power furnaces. high arcing mode to a low resistive mode The objective is to maintain both electrode penetration and power input. But each 105 electrode will behave individually and Fortunately, most large furnaces have depending on the arcing conditions, will individual tap changers on three separate experience changes in resistance of several transformers. It is thus possible to lower hundred percent under extreme conditions. the voltage on one or more transformers to Moving an electrode in to compensate is remain within the protection limits, while not a problem if you know its resistance. If minimising the power loss.
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