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Relation Between Active Power of the Submerged Arc Furnace and the Electric Energy Consumption Indicator in the Process of Ferrosilicon Smelting

Machulec B., Bialik W., Gil S.

Archives of Metallurgy and Materials

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2019

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Vol. 64, iss. 2

633--638

EN

Higher active power of a submerged arc furnace is commonly believed to increase its capacity in the process of ferrosilicon smelting. This is a true statement but only to a limited extent. For a given electrode diameter d, there is a certain limit value of the submerged arc furnace active power. When this value is exceeded, the furnace capacity in the process of ferrosilicon smelting does not increase but the energy loss is higher and the technical and economic indicators become worse. Maximum output regarding the reaction zone volumes is one of parameters that characterize similarities of furnaces with various geometrical parameters. It is proportional to d3 and does not depend on the furnace size. The results of statistical analysis of the ferrosilicon smelting process in the 20 MVA furnace have been presented. In addition to basic electrical parameters, such as active power and electrical load of the electrodes, factors contributing to higher resistance of the furnace bath and resulting lower reactive power Px demonstrate the most significant effect on the electrothermal process of ferrosilicon smelting. These parameters reflect metallurgical conditions of ferrosilicon smelting, such as the reducer fraction, position of the electrodes and temperature conditions of the reaction zones.

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Application of the Mining Industry Wastes as Raw Material for Melting of the Complex Fesial Ferroalloys

Machulec B., Bialik W., Gil S.

Archives of Metallurgy and Materials

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2018

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Vol. 63, iss. 2

975--979

EN

An economical alternative for the steel industry which uses a separate ferrosilicon and aluminum for the deoxidization of steel is a complex deoxidizer in the form of FeSiAl alloys. The effectiveness of complex deoxidizers is higher and they have a positive effect on quality improvement and also for mechanical properties of the finished steel. It is associated with a smaller number of non-metallic inclusions and a more favorable its distribution in the structure of steel. Noteworthy are the waste from the mining industry simultaneously contains SiO2 and Al2 O3 oxides with a few of dopants in the form of CaO, MgO, FeO, TiO2 oxides. These wastes are present in large quantities and can be a cheap raw material for obtaining complex FeSiAl ferroalloys by an electrothermal method. “Poor” hard coal grades which so far did not apply as a reducing agent in the ferroalloy industry because of the high ash content can also be a raw material for the electrothermal FeSiAl process. The electrothermal FeSiAl melting process is similar to the ferrosilicon process in the submerged arc furnace. For this reason, a model based on Gibbs’ free enthalpy minimization algorithm was used to analyze the simultaneous reduction of SiO2 and Al2 O3 oxides, which was originally elaborated for the ferrosilicon smelting process. This is a system of two closed reactors: the upper one with the lower temperature and the lower one with the higher temperature. Between the reaction system and the environment, and between the reactors inside the system, there is a cyclical mass transfer in moments when the state of equilibrium is reached in the reactors. Based on the model, the basic parameters of the electrothermal reduction process of SiO2 and Al2 O3 oxides were determined and a comparative analysis was made towards the ferrosilicon process.

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Wpływ zanieczyszczeń surowców na proces technologiczny wytopu żelazokrzemu

Machulec B., Bialik W.

Hutnik, Wiadomości Hutnicze

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2013

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Vol. 80, nr 6

411--414

PL

Bazując na algorytmie minimalizacji Gibbsa (FEM) oraz modelu fizykochemicznym, przedstawiono wyniki obliczeń teoretycznych dotyczących wpływu składu chemicznego surowców na proces elektrotermiczny wytopu żelazokrzemu. W obliczeniach wykorzystano możliwości, jakie stwarza włączenie do najnowszej wersji pakietu do obliczeń termochemicznych HSC 6.1 dodatku umożliwiającego korzystanie z bazy danych termochemicznych i rozwiązywanie zagadnienia FEM bezpośrednio na arkuszu kalkulacyjnym Excel. Jako model procesu elektrotermicznego wytopu żelazokrzemu w piecu rezystancyjno-łukowym wykorzystano układ złożony z dwóch reaktorów izotermicznych: górnego o temperaturze niższej T1 i dolnego o temperaturze wyższej T2 . Pomiędzy reaktorami i otoczeniem oraz pomiędzy reaktorami wewnątrz układu, zachodzi cyklicznie wymiana masy w chwilach gdy w reaktorach osiągnięty jest stan równowagi.

EN

Based on the Minimum Gibbs Free Enthalpy algorithm (FEM) and model of the reaction zones located around electrode tips in the submerged arc furnace, analysis of the raw materials chemical composition influence on the ferrosilicon smelting process was carried out. In the calculations new opportunities created by the HSC 6.1 software package which enables the use of a thermochemical database and equilibrium calculations directly in the Excel spreadsheet have been utilized. As a model of the ferrosilicon process in the submerged arc furnace is a system of two closed isothermal reactors: an upper one with a lower temperature T1 , and a lower one with a higher temperature T2 . Between the reactors and the environment as well as between the reactors inside the system, a periodical exchange of mass occurs at the moments when the equilibrium state is reached.

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Badania statystyczne wpływu wybranych parametrów elektrycznych pieca rezystancyjno-łukowego na jednostkowy wskaźnik zużycia energii w procesie wytopu żelazokrzemu

Trederowski T., Kopeć G., Machulec B.

Prace Instytutu Metalurgii Żelaza

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2010

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T. 62, nr 3

30-33

PL

W artykule przedstawiono wyniki badań statystycznych obejmujących 10-letni okres czasu pracy pieca żelazokrzemowego o mocy 20 MVA. Przedstawiono zależności pomiędzy wybranymi parametrami elektrycznymi, a jednostkowym wskaźnikiem zużycia energii. Badania obejmują okres pracy pieca w którym począwszy od 2000 roku zdołano radykalnie poprawić wskaźniki techniczno-ekonomiczne.

EN

This article presents the results of 10 years of statistical research of 20 MVA ferrosilicon furnace run time. There are shown dependencies between selected electrical parameters and specific energy consumption ratio. The studies include the period of furnace run time since 2000 when the technical- economical indicators were successfully improved.