Our invention makes possible the continuous melting of ferrous materials such as sponge iron, scrap iron or iron ore in an electric arc furnace so that the electric arc is never turned off nor is the power ever reduced.
This invention assures the continuous melting of ferrous materials, the simultaneous and continuous refining of molten steel by a means that prevents contamination from the metal charge and eliminates the danger of clogging the tapping hole, and the semi-continuous tapping of molten steel when it is adequately refined.
Most operations aim for 2 to 3 buckets of scrap per heat and will attempt to blend their scrap to meet this requirement. Our invention achieve a single bucket charge.
Constant flat bath allows for high electrical efficiency if a good foamy slag is maintained !
Otherwise – damage to refractory, accelerated delta wear, increased electrode consumption, decreased yield, increased power consumption, increased wear on oxygen lance.
Specific Objectives of New Process
- Lower specific capital costs
- Lower primary energy consumption
- High productivity/low conversion cost
- Flexibility in choice of feed materials
- Lower T-T-T closer
- Maintain maximum process flexibility
- Increase product quality while maintaining cost competitiveness
- More environmentally friendly and meet environmental requirements at minimum cost
- Maximizing power input to the EAF by using a combination of energy sources
- Optimized energy use and electrical power supply optimized to minimize losses
This invention offers many features that are not available in the present art:
- The charge is continuous and several types of materials can be charged simultaneously;
- The required melting time is reduced because the furnace works continuously;
- Heat and emissions released into the environment are reduced because the furnace always works with closed cover;
- All motions required for charging, melting, refining and tapping the steel are automated;
- The furnace tilting motion enables the steel to be refined during the melting process thus assuring a precise control of the steel temperature and composition;
- Dust dispersion is reduced and, therefore, transformation yield is improved;
- Modern operations aim for a tap-to-tap time of less than 45-50 minutes. We aim for achieving tap-to-tap times of 40 to 45 minutes.