Enhancing the Service Life of DC Electric Arc Furnaces

In light of the evolving trends in electric furnace steelmaking and the increasing popularity of refractory material general contracting, it is imperative to focus on optimizing refractories for electric furnaces as part of a comprehensive refractory management strategy. The longevity of an electric smelting furnace is intricately linked not only to the design and material selection of the refractory components but also to their quality and the level of maintenance provided.

Furnace body maintenance encompasses more than just routine oven care, furnace repairs, and general upkeep; it also involves ensuring production continuity, maintaining optimal equipment conditions, selecting appropriate refractory materials, choosing suitable raw materials, formulating effective smelting processes, and implementing scientific management and operational practices.

Let's delve into specific operational strategies aimed at extending the service life of electric furnaces:

1.1 Temperature Control During Steel Tapping

Adjust the tapping temperature of the electric furnace from its original setting of greater than 1630°C to a more controlled range of 1620°C ± 10°C. Strictly prohibit high-temperature tapping, particularly for heats exceeding 1650°C. Currently, the average tapping temperature of electric furnaces has been reduced from 1636°C at the beginning of the year to 1630°C, with the proportion of high-temperature steel (tapping temperature ≥ 1650°C) kept below 10%.

1.2 Tapping Composition Control

Ensure that the tapping composition, specifically the carbon content, is maintained at ≥0.06%, and strictly control the number of peroxidation furnaces. In the event of peroxidation, implement timely remedial measures within the furnace (such as in-furnace deoxidation). A novel post-furnace decarburization process has been developed for low-carbon steel grades (finished products ≤0.06%). Presently, the average tapping carbon content of electric furnaces has increased from 0.05% at the start of the year to 0.071%, with the tapping rate exceeding 60%.

1.3 Slagging Management

Through continuous tracking and analysis of slag composition, adjust the input method and timing of auxiliary materials like lime and slag regulators to establish a correlation between the two. Concurrently, effectively integrate the entire foaming slag process to ensure the formation and maintenance of a protective layer on the furnace wall. The amount of slag regulator added has increased from 4 Kg/t.s at the beginning of the year to 5.8 Kg/t.s.

1.4 Bottom Electrode Temperature Monitoring

Monitor the temperature and flow rate of the cooling water for the bottom electrode throughout the smelting process:

• Back Pressure Control: Ensure that the back pressure of the 04 system remains below 4.2 Kg. If exceeded, notify the water treatment department to flush the system.
• Cooling Water Flow Rate: Maintain a cooling water flow rate of at least 90 NM³/h for the bottom electrode. If the flow rate drops below this level, flush the filter. Additionally, if the bottom electrode temperature triggers an alarm, investigate the cause promptly; otherwise, empty the furnace body to inspect the furnace bottom.
• Temperature Tracking: Continuously track and analyze the temperature at 18 points along the bottom electrode.
• System Cooling Water Monitoring: Monitor the temperature of the cooling water within the system. If it exceeds 38°C, notify the water treatment department to initiate air cooling measures.

By implementing these specific operational strategies, we can significantly enhance the service life of DC electric arc furnaces, thereby improving overall production efficiency and reducing operational costs.
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