Smelting — Submerged Arc Furnace (SAF) Operation
Metallurgical smelting process for 3-electrode Submerged Arc Furnaces operating at 1400-1600°C.
Metallurgical Process Steps
CHARGING
Continuous/batch charging of mix into furnace through charging chutes.
SMELTING
3-electrode SAF (22.5 MVA) operating at 1400-1600°C with baked/self-baking electrodes forming slag & metal.
TAPPING EXECUTION
Executed every 2–2.30 hrs by burning taphole with oxygen pipe, metal + slag flowing to ladles/granulation.
ELECTRODE MANAGEMENT
Slipping, casing welding, paste charging, maintaining electrode length/current, which is the key factor of Operation.
Operational Observation: ERAMET Not able to maintain properly
Furnace Mechanical Maintenance
- • Furnace shell & refractory lining inspection
- • Taphole drilling machine & mud gun maintenance
- • Electrode column, slipping clamps, & pressure rings
- • Contact shoes & bus tube cooling maintenance
- • Hydraulic systems for electrode regulation
- • Fume extraction ducts, bag house, & ID fans
Furnace Electrical Maintenance
- • Furnace transformer (33kV to 80-200V)
- • OLTC & RTCC panels testing
- • Thyristor / PLC based electrode regulation system
- • CT/PT, HT/LT switchgear, capacitor banks for PF correction
- • Electrode hoist motors & hydraulic power pack controls
- • Temperature/level sensors & furnace SCADA