21000kVA SUBMERGED ARC FURNACE TECHNICAL PROPOSAL PDF

Add: No.2-1803 Soubao Business Center, No.16 South-West Third Ring Road, Beijing, China..
PC100068
E-mailsales2015@bidboiler.com TEL: 0086-10-57011358 FAX:0086-10-56298980

21000KVA SUBMERGED ARC
FURNACE TECHNICAL PROPOSAL

Beijing Bidragon Machinery Co.,Ltd

2014.9.5

Add: No.2-1803 Soubao Business Center, No.16 South-West Third Ring Road, Beijing, China.. PC100068

Summary
When technological parameters just conform to production of high carbon
ferromanganese, then it would not guarantee the production of silicon manganese,
but conversely it could, however it could slightly affect the technical index of high
carbon ferromanganese, so this technical proposal is mainly base on the production
parameters of silicon manganese, also can produce high carbon ferromanganese.
This technical proposal has considered the technology of non-flux smelting for high
carbon ferromanganese, and the recycle problem of rich-manganous slags. The
produced products include silicon manganese, high carbon ferromanganese,
rich-manganous slags.
The trademark, raw materials requirement, technical and economical indexes for two
types of products are as follows:

I. Production technology
I. The trademark of high carbon ferromanganese and silicon manganese

Trademark and chemical component of high carbon ferromanganese
Trademark
Chemical component /%
Mn C
Si P
S
1 Batch 2 Batch
I
Grade
II
Grade

FeMn75C7.5 75.0 7.5 1.5 2.5 0.20 0.33 0.03
FeMn70C7.0 70.0 7.0 2.0 3.0 0.20 0.38 0.03
FeMn65C7.0 65.0 7.0 2.5 4.5 0.20 0.40 0.03

Trademark and chemical component of silicon manganese
Trademark
Chemical component%
Mn Si
P
S
C

FeMn64Si27 60.067.0 25.028.0 0.5 0.10 0.15 0.25 0.04
FeMn67Si23 63.070.0 22.025.0 0.7 0.10 0.15 0.25 0.04
FeMn68Si22 65.072.0 20.023.0 1.2 0.10 0.15 0.25 0.04


FeMn64Si23 60.067.0 20.025.0 1.2 0.10 0.15 0.25 0.04
FeMn68Si18 65.072.0 17.020.0 1.8 0.10 0.15 0.25 0.04
FeMn64Si18
60.067.0 17.020.0
1.8 0.10 0.15 0.25 0.04
FeMn68Si16
65.072.0 14.017.0
2.5 0.10 0.15 0.25 0.04
FeMn64Si16
60.067.0 14.017.0
2.5 0.20 0.25 0.30 0.05

II. Raw materials requirement
The raw materials are the basic foundation for smelting finished product, and the
qualified raw materials are important conditions for guarantee product quality, so the
raw materials must conform to technical requirement.
2.1 Raw materials requirement of high carbon ferromanganese
The raw materials for smelting high carbon ferromanganese: manganese ore,
rich-manganous slags, coke, lime, fluorite and electrode paste.
No. Name
Qualified lumpiness
mm
Physical and chemical properties
1
Manganese
ore
5100 10mm<15%
Mn30% SiO
2
20%
AL
3
O
2
7% P0.04%
S0.02%
2
Metallurgical
coke
320
Solid C84% S<0.05% Ash content
14% Outer moisture6%
3 Lime
1060/ 10mm less
than 5%
CaO85% SiO
2
5% H
2
O<1% S0.02%
4 Fluorite 1060
CaF
2
72% AL
3
O
2
0.6% CaCO
3
0.55%
SiO
2
26% S0.02%
5
Electrode
paste
<100
Standard electrode pasteYB/T5215-96
No.I
Note: 1.The manganese ore, rich-manganese slags are piled up in the open air, the
coke and lime are piled in sheds, electrode paste are piled in warehouse.
2. The fluorite is additives for adjustment of furnace condition, one set of
furnace can consume 43.5 ton.
3. Adopt non-flux method for smelting high carbon ferromanganese, do not
add lime.

2.2 Raw materials requirement of silicon manganese
The raw materials for smelting silicon manganese: manganese ore,
rich-manganous slags, coke, silica, dolomite, fluorite, electrode paste.
No. Name
Qualified lumpiness
mm
Physical and chemical properties


1
Manganese
ore
5100 10 <15%
Mn4652% Fe78% SiO
2
5.56%
AL
3
O
2
1.21.5% P0.020.04%
2
Metallurgical
coke
518
Solid C80% P<0.05% Ash content15%
Outer moisture10%
3 Silica 1040 SiO
2
97% P
2
O
5
0.05% Fe<0.1%
4 Dolomite 2060 MgO19% CaO20% P<0.05%
5 Fluorite 1060
CaF
2
72% AL
3
O
2
0.6% CaCO
3
0.55%
SiO
2
26% S0.02%
6
Electrode
paste
<100 Standard pasteYB/T5215-96No.I
Note: 1.The manganese ore, rich-manganese slag and silica are piled up in the open
air, coke and lime are piled in sheds, electrode paste are piled in warehouse.
2. The fluorite is additives for adjustment of furnace condition, one set of
furnace can consume 43.5 ton.

III. Technical economic index
High carbon ferromanganese technical economic index
No. Name Unit Index Remarks
1 Manganese ore kg
18001900
Include 34% of
manganese
2
Rich-manganese
slag
kg 580600
Include 40% of
manganese
3 Lime kg 700720 Do not add flux
4 Coke kg
350370

5 Power consumption kW.h 28003000
6
Recovery rate of
manganese
% 7275

Silicon manganese technical economic index

No. Name Unit Index Remarks
1 Manganese ore kg 16001700
Include 33% of
manganese
2
Rich-manganese
slag
kg 520550
Include 38% of
manganese
3 Silica kg
330350

4 Coke kg 550580


5 Dolomite kg 350400
6 Fluorite kg 100150
7 Power consumption kW.h
46004800

8
Recovery rate of
manganese
%
8385

IV. The output theoretical calculation
4.1. 21000kVA high carbon ferromanganese furnace output theoretical
calculation
Q=24CosPsk
1
k
2
k
3
W
=240.76210000.950.980.952900
117t/d

Note: Q Daily output per furnacet/ d
h---- Production time per day 24h/d
CosPower factorcalculated by 0.76
P
S
----- Rated powerKVA
K
1
Coefficient of fluctuationPrimary voltageK
1
=0.95
K
2
Utilization factor of transformer powerK
2
=0.98
K
3
Time factorOperation rateK
3
=0.95
WPower consumptionW=2900 KWh

4.2. 21000kVA silicon manganese output theoretical calculation
Q=24CosPsk
1
k
2
k
3
W
=240.78210000.950.980.954200
83t/d

Note QDaily output per furnacet/ d
h------ Production time per day 24h/d
CosPower factor0.78
P
S
---- Rated powerKVA


K
1
Coefficient of fluctuationPrimary voltageK
1
=0.95
K
2
Utilization factor of transformer powerK
2
=0.98
K
3
Time factorOperation rateK
3
=0.95
WPower consumptionW=4200 KWh

V. Brief introduction of production process
5.1 High carbon ferromanganese production process flow diagram

The qualified raw materials and auxiliary materials, including manganese ore,
rich manganese slag, lime, reducing agent, flux, electrode paste, etc., are transported
to factory area after wagon balance by trucks, and separately stored in relevant raw
materials storage yard, all kinds of raw materials are mixed together according to the
Manganese ore Coke Lime Rich-manganese slag
Automatic burdening and weigh
Belt conveyor charging
21000KVA high carbon
ferromanganese furnace
Electrode paste
Cooling water
35KV power source
Iron output
Casting ingot
Finishing
Packaging and leave factory
Chimney
Air cooler
Preprocessor
Draught fan
Slag output
Dust remover
Continuous casting machine


formula of smelting alloy, then elevated to the platform of 27m delivered by belt
conveyor, the rotary distributor deliver the mixed materials to lower stock bin, and fall
into furnace through blanking pipe.
The furnace burden are charged into semi-closed submerged arc furnace,35KV
power source are lead into furnace through three-phase electrode by transformer, the
voltaic arc heat generated between electrode and furnace burden are transferred to
furnace chamber, through voltaic arc heat and resistance heat, so the mixture of
manganese ore and rich manganese slag can reduce to high carbon ferromanganese,
during the whole process of smelting, the voltage classes and current intensity of
electrode are decided by smelting technical parameters, the value of voltage and
current in different times, that means the input power to furnace is different, the
electrode is inserted in furnace burden, and the gas escape from the surface of
materials. The voltaic arc keep not exposed, the blending furnace materials are feed
into furnace following with the declining of charge level, that will keep certain height of
in-furnace charge level, and there is a flat cone shape around electrode, the reduced
high carbon molten ferromanganese store to certain level, use opener to open
furnace mouth and release molten iron and slag, remove the slag in alloy, then pour
into ingot in mould. The alloy ingots are delivered to finished products warehouse
after cooling and crushing. The electric furnace must supply power under stipulated
power supply standard. The electric furnace can tap iron once every 2.5 hours, and
output 9~10 batches per day, the output is about 13 ton. The winch will pull the ladle
car to casting workshop, the crown block hoist the ladle after 20 minutes of cooling,
and pour molten ferromanganese into ingot mould. The cooled alloy are levered, and
hoisted to iron container and put into storage.
The smelting and pouring are triple-shift work system, the annual work time are 330
days. The high carbon ferromanganese tap dry slag, which overflow from ladle to slag
tanks, the slag and iron are transported out after one batch, the crown block hoist the
slag ladle and pour into continuous casting machine.
It is necessary to sample and analyze the output iron every time, the analysis result
must be offered to furnace supervisor.
The smoke enter into dust discharge flue through smoke absorption hood, and
arrange bag type dust collector beside or behind the plant workshop, the smoke dust
enter into dust collector after pre-processor, the effluent concentration after treatment


can conform to stipulated emission standard.
The circulating cooling water is supplied by pump station, and the cooling water flow
back to water tank because of natural drop after entering furnace, then which is
supplied to front furnace by pump after natural cooling in tank.

5.2. Silicon manganese production process flow diagram

The qualified raw materials and auxiliary materials, including manganese ore,
rich manganese slag, silicon, reducing agent, flux, electrode paste, etc., are
transported to factory area by trucks after wagon balance, and separately stored in
relevant raw materials storage yard, all kinds of raw materials are mixed together
Manganese ore Coke

Silicon Rich manganese slag
Automatic burdening and weighing
Belt conveyor charging
21000KVA Silicon
manganese furnace
Electrode paste
Cooling water
35KV power source
Iron tapping
Casting ingot
Finishing
Packaging and leave factory

Chimney
Air cooler
Preprocessor
Draught fan
Water slag output
Dolomite
Dust collector


according to the formula of smelting alloy, then elevated to the platform of 27m
delivered by belt conveyor, the rotary distributor deliver the mixed materials to lower
stock bin, and fall into furnace through blanking pipe.
The furnace burden are charged into semi-closed submerged arc furnace,35KV
power source are lead into furnace through three-phase electrode by transformer, the
voltaic arc heat generated between electrode and furnace burden are transferred to
furnace chamber, through voltaic arc heat and resistance heat, so the mixture of
manganese ore and silicon can reduce to silicon manganese alloy, during the whole
process of smelting, the voltage classes and current intensity of electrode are
decided by smelting technical parameters, the value of voltage and current in different
times, that means the input power to furnace is different, the electrode is inserted in
furnace burden, and the gas escape from the surface of materials. The voltaic arc
keep not exposed, the blending furnace materials are feed into furnace following with
the declining of charge level, that will keep certain height of in-furnace charge level,
and there is a flat cone shape around electrode, the reduced high carbon molten
ferromanganese store to certain level, use opener to open furnace mouth and release
molten iron and slag, remove the slag in alloy, then pour into ingot in mould. The alloy
ingots are delivered to finished products warehouse after cooling and crushing. The
electric furnace must supply power under stipulated power supply standard. The
electric furnace can tap iron once every 2.5 hours, and output 9~10 batches per day,
the output is about 10 ton. The winch will pull the ladle car to casting workshop, the
crown block hoist the ladle after 20 minutes of cooling, and pour molten
ferromanganese into ingot mould. The cooled alloy are levered, and hoisted to iron
container and put into storage.
The smelting and pouring are triple-shift work system, annual work time are 330 days.
The water slag overflow from ladle to slag tanks, then flow into slag groove, flush into
slag tank at the end of groove, then transported to slag yard by submerged chain
conveyor.
It is necessary to sample and analyze the output iron every time, the analysis result
must be offered to furnace supervisor.
The smoke enter into dust discharge flue through smoke absorption hood, and
arrange bag type dust collector beside or behind the plant workshop, the smoke dust
enter into dust collector after pre-processor, the effluent concentration after treatment


can conform to stipulated emission standard.
The circulating cooling water is supplied by pump station, and the cooling water flow
back to water tank because of natural drop after entering furnace, then which is
supplied to front furnace by pump after natural cooling in tank.

VI. Workshop layout
6.1 Unit set submerged arc furnace smelting span
This span is multi-story factory, there is arranged with electrical room in the north of
factory, and one set 21000KVA submerged arc furnace: the span of transformer is
7.5m36m, smelting area span is 15m36m, casting area span is 24m36m,the
space between center line of silicon manganese furnace and lateral axial line is 6m,
all the platforms are arranged are shown in the following table:
No.
Level of
platform
(m)
Main equipment Remarks
1 0.00
121000kVA Submerged arc furnace proper, 2 baffles of iron
output mouth,2 opener and mutegun, ladle car, slag ladle car,
steel rail, vertical winch, iron ladle, slag ladle.

2 +7.00
Operation platform, smoke hood, short-net, holder, blanking
tube, in-furnace cooling water, high and low voltage cabinet
2
th
floor
3 +11.00 Transformer
2.5
th

floor
4 +16.00
Electrode steel suspension platform, hydraulic system,
pneumatic system
3
th
floor
5 +21.00 Electrode paste charging platform 4
th
floor
6 +27.00 Materials feeding bin, rotary belt conveyor 5
th
floor
7 +34.00 10t single beam crane Roof
In order to improve the labor environment in workshop, the electric furnace apply low
smoke hood water cooled smoke discharge, at the both ends of workshop arrange
hatches of 2.5m2.5m can elevate to 7m and 27m platform for delivery of electrode
paste and electrode shell.
6.2. Casting area span This span is single layer plant, the occupied area is
24m36m=864 , and equipped with 1 set electric overhead travelling crane of
Q=32/10tLk=22.5mJc=40%,the standard height of rail level is +13.00m. Besides
pouring work zone, there is reserved ladle engineering work zone at both ends of
workshop. 1 set furnace is equipped with 5 set ladles and 6 set slag ladles. 1 set
furnace is equipped with one whole set of ingot mould, the finished products are


delivered by flat cars to storage house.

VII. Finished products warehouse, maintenance shop, control lab, material
depot
7.1 Finished products warehouse: this warehouse is for crushing, finishing and
storage of alloy products delivered from furnace pouring span, and packaged
according to the requirement of clients.
Overall dimension of storeroom: 18m72m=1296 ,the inventory is for 1 month.
Configured equipment: 1 set of 10t double beam crane
7.2 Maintenance shopmainly for maintenance, repair of furnace, manufacture of
electrode enclosure, maintenance of electrical equipment.
Overall dimension of plant: machine maintenance: 12m24m=288
electrical maintenance: 12m12=144

Configured equipment: 1 set of 5t single beam crane, plate shearing machine, rib
plate coiling machine, bench drill, electric welding machine, etc.

7.3 Control lab12m16m=192 ,mainly for chemical component analysis and
alloy products.

II. Technical specification and description of equipment
1. Main parameters of 21000kVA submerged arc furnace
Secondary voltage
Silicon manganese alloy usually use secondary voltage wave at 165/171V, and high
carbon ferromanganese at 156/162V, this technical proposal consider both smelting
conditions.
The secondary voltage of transformer is at 132~153~186V (grade difference is 3V,
total 19 grades), when star angle change, the lowest voltage is 76.2V, then the new
furnace can directly bake electrode, this will help electrode baking when new furnace
start or have accident.


Diameter of electrode 1350mm
When at 165V ( silicon manganese alloy),the current density is 5.14A/cm, and when
at 156V(high carbon ferromanganese) , the density is 5.43 A/cm. This can apply for
both the requirement of silicon manganese and high carbon ferromanganese.
Diameter of electrode circle 3300
The power density of electrode circle is 1842kw/m,it is smaller for production of
silicon manganese, and bigger for high carbon ferromanganese.
Diameter and depth of furnace hearth
The diameter of furnace hearth is 8000mm, the depth is 3200mm. The area power
density is 357kw/m, the volume power density is 111 kw/m,it can basically meet the
production requirement of silicon manganese, and it is bigger for high carbon
ferromanganese, and it will increase number of iron tapping and water cooling
furnace shell to make up for this.
1.1 Technical parameters of furnace proper
No. Technical parameters 21000kVA
1 Diameter of furnace shellmm 10000
2
Height of furnace shellmm
5500
3
Diameter of furnace chambermm
8000
4
Depth of furnace chambermm
3200
5 Diameter of electrodemm 1350
6 Working stroke of electrodemm 1400
7 Diameter of electrode circlemm 3300100
8 Fluctuation speedm/min 0.5
9
Number of iron output mouth/included
angleUnit
2/150
10
Consumption of cooling water t/h
450
11
Days of annual production d/a
330

1.2 Technical parameters of transformer
1.2.1 Mono-phase transformer
ModelHKDSPZ-7000kVA/35kV 3 set
Rated capacityKVA21000permitted overload of 20%


Cooling methodOFWFForced oil water cooling, the inlet water temperature is
not higher than 32,the outlet water temperature is not higher than 45.
Primary voltageKV35
Secondary voltage(V):132153186Vgrade difference is 3Vtotal 19
grades
Secondary rated voltage (V):153V
Short circuit impedance: when at 153V6%coil internal impedance5%
Voltage regulating mode: power-driven load voltage regulation
Cooling method: Forced oil circulating water cooling
Lateral outlet line terminal: 20 units

1.3 Busbars electrical data
Conductive copper tube current density:2.53A/mm
2

Pickup current density between conductive elements and electrode:1.5
2.0A/cm
2.
Water cooled cable current density :2.53A/mm
2
Degree of unbalance for busbars: <5%
Permitted electrode current density: 5.527.18A/cm
2

1.4 Requirement of cooling water
Water capacity (m
3
/h per set):450
Pressure(MPa): 0.20.3
Cooling water quality: PH: 68
Total hardness: <10mg/L(CaO)
Suspended solid: <10mg/L
Inlet water temperature: <35

2. Description of equipment
The main equipment of 21000KVA submerged arc furnace use short smoke hood
semi-closed fixed furnace type. The design of electrode adopts hydraulic piston
elevation system, the busbars adopt water cooling cable, water cooling copper tube,


forged cooper tile, etc. The equipment composition of main part: furnace proper,
smoke hood and chimney, electrode part(include holder, elevation system, electrode
slipping device, pressure ring device),opener and mutegun system, hydraulic
pneumatic system; the composition of auxiliary equipment: raw material feeding
system, double beam bridge crane, iron tapping system, slag tapping system, casting
system, etc.

2.1 Main equipment of furnace
Transformer of electric furnace
Model of mono-phase transformerHKDSPZ-7000kVA/35kV 3 set
Rated capacityKVA 7000permit overload of 20%
Cooling type OFWF3245
Primary voltageKV 35
Secondary voltage(V) 132153186V(Grade difference is 3V
total 19 grades
Secondary rated voltage (V): 153V
Short circuit impedance: when at 153V6%coil internal impedance5%
Interface type Iio
Pressure regulating method:power driven load voltage regulation
Insulation level BIL480Ac200
Cooling typeForced oil circulating water cooling
Lateral outlet line terminal: 20 units of outlet line copper tube 70/50
0
-0. 02
length
220 mm
Three-phase cascade group /YY connection type for initial
shaping/Normal smelting
FrequencyHZ 50
Furnace shell
The furnace shell is rolled by steel plate 20,transverse and vertical rib plates 20,the
width is 250mm,the distance between is 1m. The baseplates is made of steel plate


25, and supported by double T-steel in 45 radiation shape.2 furnace nozzles are
made of 25 steel plate,and arranged in 150 shape.
The material of steel plate: Q235-A. There is installed with 3 thermicouples under the
furnace shell
for testing furnace lining temperature. The bottom of furnace shell should equip with
forced wind cooling device.
Diameter of furnace shell10000
Height of furnace shell: 5500
Furnace lining
The furnace wall is built by high aluminum bricks, and use clay bricks above slag line,
the furnace bottom is built by carbon bricks,lay foundation by high aluminum bricks
and clay bricks. It is necessary to leave thermal expansion joint150mm between
furnace lining and shell, and filled with refractory fibrofelt, asbestos board,etc.
Diameter of furnace hearth8000
Depth of furnace hearth: 3200
Furnace bottom Air cooling device at furnace bottom
The air cooling function is supplied by draught fan, and lead to center of funace
bottom through pipeline (steel plate 5 ),then disperse along with radiation T-steel
after cold and hot exchange.
Air capacity: Q=82000m
3
/h
Total pressure:P=1800Pa
Power of electric motor:N=75kW380V
Diameter of pipeline: 1200
Water cooling smoke hood
The outline is dodecagon vault construction. Twelve water cooling columns support
one set of water cooling framework beam of turtle back shape,there is insulation
between framework beam and column, and insulation between column and furnace
shell, and filled with high aluminum ramming materials between framework
beams(there is stainless steel bar mesh12), there is two kinds of cover plates above,
the outer ring is carbon steel water cooling cover plate, the triangle center zone is
stainless steel water cooling cover plate. There is dodecagonal smoke hood walls


between columns, and leave three doors, nine small doors. The side plate inside
hood, big and small doors, columns are welded with slag hanging nail, and with
80mm thick high aluminum ramming materials.
Smoke hood diameter10600
Height of smoke hood: 2200
Chimney
There are two water cooling smoke tubes on top of water cooling smoke hood
(steel plate10),and insulation between cover plates. And there is single wall smoke
tube (steel plate 6 ). Also insulation for chimney at every storey of building, there is
pneumatic butterfly bamper for closing chimney and preserved mouth of dust flue,
and equipped with raincap for single wall chimney top, and lighting rod on top of
raincap.
Diameter of chimney1700
Standard height of chimney: +40.000
Busbars
The electric furnace adopts three mono-phase transformer for power supply,and use
water cooling secondary tubular structure bus system for power supply between
transformer and electrode, secondary bus system include cast copper connector,
conductive copper tube, water cooling cable, insulated hoisti ng system, water cooling
copper tile, etc. Three mono-phase transformer and busbars form in 120 distribution,
each phase has 10 groups, total 20 bars.
Copper tube specification7010
Water cooling cable: 1800mm
2
2.6m
Holder
The specification for circle diameter of three sets holders is3300100, the
diameter for each set of electrode is 1350, the elevation of electrode adopts 2 sets
of overhung type oil cylinder 250, the stroke is 2000mm. The electrode slipping
device adopts hydraulic mechanical brake control and slipping oil tank, the stroke is
2050mm. It can realize slipping with electricity, and the conduction adopts water
cooling copper tube and forged copper tile, water cooling jacket and lower holder tube
use stainless steel 1Cr18Ni9Ti.


Circle diameter 3300100
Diameter of electrode 1350
Elevation speed 0.5m/min
Hoist cylinder: 250 /2.0m
Slipping oil cylinder: 150 /0.05m
Width of copper tile 380
Length of copper tile 1000
Thickness of copper tile 90
Water cooling system
Two sets of water dispensers are located at both sides of +7.000 platform, the water
source is supplied by water pump station, this system pump softened water (0.25Mpa)
to busbars,copper tile, pressure ring ,water cooling protection screen for cooling, and
pump ordinary water (0.25Mpa) to smoke hood, water cooling chimney, hydraulic
station for cooling. Another line of softened water (0.05Mpa) is pumped to forced oil
water cooling devide of transformer, there are air inflation and blow-down
device,which is used for fast-draining when blowing-out for maintennance. Every
water dispenser has sound and light alarm device for pressure and temperature.

Hydraulic system
The hydraulic system supply the function of regulation control for electrode elevation,
electrode slippong,material tube scallop valve,circular material distributor door
release structure.It is composed of hydraulic station, hydrailic pipline, 3 sets of
electrode and material tube scallop valve station, 3 sets of circular material distributor
valve station. The hydraulic station should meet the requirement for elevation of 2
sets of electrode system at the same time, pressure supply should meet the
requirement for working under 6Mpa.

Oil tank capacity2000L
Plunger pump: rate of flow 80L/min pressure 12Mpaelectrical motor 22kW,
one used, one backup
Hydraulic oilHM46


Cleanliness degreeNAS7 degree
Charging system
13 sets of stock bin (6 m
3
) is ditributed in circular shape, furnace core (1 unit) and big
charge level(3 units) are separately feed by one stock bin and there are 4 stock bins
totally. Small charge level(9 units) are supplied by one stock bin. Every stock bin is
equipped with one enclosed hydraulix scallop valve,all the material tubes are
37712mm,furnace core,alternating area near by busbars use stainless steel
material tube 1Cr18Ni9Ti, other tubes use ordinary tubes Q235-A.
Stock bin capacity: 6m
3

Diameter of material tube: 377 12
2.2 Auxiliary equipment of furnace
Opener and mutegun system
2 set opener and mutegun systemTHJ1800-12 2 set of rails 43Kg/m-26m
1 set of gasholder6m
3

Travelling system
No. Name Specification Qty Lifting height Workshop
1
Electric double-beam
bridge crane
QD-40/10-22.5-A6 1 13m Casting span
2
Electric single beam
crane
QD-10-16.5-A5 1 10m
Finished
products span
3
suspension crane
LX-2-10-A5 1 34m
Electric furnace
span
4
motor hoist
LX-2-10 1 6m
Electrode
collection and
installation
5
Electric double beam
grab crane
10t K=13.5m 1 14.5m
Water slag
span

2.3 Electrical part
The electrical equipment of 21000 KVA submerged arc furnace is composed of high
voltage power supply system, electric furnace transformer, busbars, lift control
system of electrode.
Transformer: adopt low wastage energy-saving transformer, lateral outlet line,
electric on-load voltage regulation, forced oil circulating water cooling, impedance
voltage is 4~6%,and it has advantages of small size, light weight, strong overload
ability, etc.
High voltage power supply system


Basic composition
35KV power supply line is built overhead, lead to factory area, then high pressure
through wall bushing, and from top to PT cabinet, PT cabinet is installed with high
voltage inlet wire disconnecting switch, voltage transformer, zinc oxide arrester, then
power supply is lead to high voltage power distribution main cabinet, this cabinet is
installed vacuum breaker, current transformer, etc.
Main parameters of high voltage switch cabinet
Rated voltage: 35kV 50HZ three-phase
Operational power supply: AC 220V
Outlet wire method: push-out
Protection degree: IP20
Disconnecting switch
Rated voltage: 35kV/50HZ
Rated current: 600A
Operation mode: manual
Disconnecting switch voltage transformer
Rated voltage35000V/3/100V/3/100V/3
Primary winding rated voltage: 35000/3V
Secondary winding rated voltage: 100/3V
Residual winding rated voltage: 100/3V
Capacity: lower than 150VA
3 sets of single phase three winding voltage transformer link group is
YO/YO/-12-11(the residual voltage winding group is connected in open-delta
shape.)
Vacuum breaker
ModelZN12-35/1250-25
Operation method: electric operation
Operation power source voltage: AC220V
Current transformer
Rated voltage: 35kV
Ratio of transformation: 300A/5A
Current transformer grade group: 0.5/10P grade
Zinc oxide arrester


Nominal voltage: 35kV
Arrester rated voltage: 42kV
Continuous running voltage: 23.4kV
Basic function
There is installed two sides of high pressure cabinet in high pressure chamber, one is
PT inlet line cabinet with built-in zinc oxide arrester, another is control cabinet with
high pressure vacuum breaker, it supply power for high pressure wingding of furnace
transformer. Zinc oxide arrester is for atmospheric over-voltage protection, and
operation over-voltage protection when vacuum breaker separate and close
transformer.
The vacuum breaker can operate on counter of high pressure cabinet, and switch on,
separate brake operation in master-control room, the disconnecting switch is
manually operated in high pressure chamber.
High pressure cabinet can display high pressure voltage and current, and installed
with electric power measurement and protection device.
Power house
The workshop operation room is installed with one side of operation platform, power
distribution cabinet, PLC cabinet. The dash board of operation platform is equipped
with 3 units of ampere meter, 3 units of primary side voltmeter, 3 units of secondary
side voltmeter and fault indicating light. The operation panel control the lifting of
three-phase electrode, automatic slipping, manual slipping and divide-shut brake of
high pressure cabinet. The workshop power distribution cabinet supply power for
hydraulic station, main transformer chamber, winch, bridge crane, vertical winch,
material distribution car, lighting distribution box of each storey of workshop, and
equipped with two sets of workshop backup power source, third floor hydraulic station
is installed with one side of control cabinet, two sets of hydraulic pump motor, two
sets of air compressor motor and direct current 24V power source, lifting system of
electrode and slipping system circuit.
21000KVA submerged arc furnace is installed with 13 sets of scallop valve operation
box in 13th floor.
The layout method of power pipeline is to use plastic power cable and lay along flat
iron hanging bracket.
Lighting


The workshop lighting power source is lead from power distribution cabinet to lighting
distribution cabinet of each storey, the controlled centrally. The switch of lighting
lamps is installed nearby the lamps.
The equipped level of electrical control system
The design principle of electric system: 1. Choose international brand; 2. General
model of electric furnace industry; 3.Quality guarantee and stable performance;
4. Convenient for application and maintenance.
Based on the above principles, high pressure electric system adopts high pressure
breaker applicable for frequent on-off, this is specially designed and configure for
electric furnace.
The low voltage control system is composed of low voltage electrical system and
automatic control system, low pressure electric system elements adopt international
known brand Schneider, intermediate relay adopts Weidmuller or Omron. PLC
system adopts German Siemens S7-300 and S7-200 system. The upper computer
adopts high performance Siemens. The display monitor is Samsung color LCD model.
The printer is HP laser printer. UPS power source is Santak brand.
The switch and indicator light use the product of Suzhou Siemens. The knife switch
and breaker use Schneider or ABB brand.
The elements selection of electric system is internationally used, advanced products
with stable performance, that will guarantee the safety and stability of control system,
and convenient for user to maintain.

2.4 Auxiliary equipment
2.4.1 Batching and charging system
The proportional qualified manganese ore, rich manganese slag, silicon, flux, coke
are unloaded to corresponding stock bins (8 units).Every stock bin is equipped with
one set electric vibrating feeder and electric scale hopper. The burdening materials
are unloaded onto batching belt by pneumatic scallop valve unload under scale
hopper, deliver to charging belt conveyor and to 22m platform, then unload the
materials to charging bin. The whole system of batching and feeding adopt PLC
control.
One electric furnace is equipped with one set of batching, feeding system.
2.4.2 Automatic charging system


27m platform is equipped with 13 units charging bin and 13 tremie pipes, among
these pipes, there is one center tremie pipe; three bedding faces are equipped with
three charging pipes; three small faces are equipped with 9 charging pipes.

The volume of charging bin is 6m
3
, and there are 13 units fixed on 27m platform,
every stock bin is equipped with one full-sealed pneumatic scallop valve and one
weighted valve. The function of weighted valve is to seal up the rising high
temperature exhaust gas when not charge materials, and pneumatic scallop valve
cant solve the problem of blocking. The number of operation button of pneumatic
valve is suspended on furnace platform according to the serial No. of tremie pipes.
The charging worker is operated before furnace, and charge materials according to
in-furnace condition, and with convenient operation and reliable charging.

2.4.3 Iron tapping and slag tapping system
The iron tapping system is composed of opener, mutegun, baffle for tapping mouth,
molten iron ladle, slag ladle, ladle transportation truck, rails, winch. The opener will
open iron notch, the slag iron flow into ladle through this notch, the alloy sink into the
bottom of molten ladle, and the slag float on the surface of ladle, after filling in the
ladle, the slag flow from long nozzle to cast steel slag ladle, the slag overflow into
tank for water quenching after filling in slag tank, which could realize t he goal for
water slag tapping. At the same time it also could flow into several cast steel slag
ladles, and realize the goal for dry slag tapping. After molten iron tapping, adopt
winch to pull ladle transportation truck and slag ladle to casting workshop. The
residual slag will be cooled and crushed after skimming, and delivered to mixing
workshop, and return to smelting furnace. The furnace slag is washed into slag tank
after water quenching, The water slag is bailed out and delivered away by 10t grab
travelling crane, if there is dry slag, lift off the slag ladle and deliver away.
No. Name Specification Qty Remarks
1 Molten iron ladle 3.5m
3
2 4 units backup
2 Cast steel slag ladle 2m
3
12 6 units backup
3
Molten iron ladle
truck
2


4 Slag ladle truck 12
5 Winch 20t 2
Rope speed
10m/min
6 Winch 8t 2
Rope speed
17m/min
7 Gantry hook 40t 1
Test lifting weight
80t
8 Ingot mould 0.2m
3
15 10 units backup

2.4.4 Casting system
The winch pull out from slag ladle to casting workshop, the slag ladle on the truck is
hoisted with 40/10t bridge crane, and pour into ingot mould of pig casting machine,
then put in storage after solidification, cooling and demould.

III. Dust collector
The dust collector equipment include dust removal system of furnace proper and
tapping notch, dust removal for furnace-top charging and material distribution
equipment, dust removal for material batching system.

3. Design basis, principle and index
3.1 Design basis
(1) Air Pollution Prevention and Control Law of the People's Republic of China
(2) Environmental Protection Law of the People's Republic of China
(3) Sanitary design of industrial enterprise TJ36---79
(4) Blowback bag type dust collector JB/T8534----1997
(5)Emission standard of pollutants of industrial furnaceGB9078-1996
Technical parameters
No. Name Unit Parameter Remarks
1 Furnace type 1 unit
Semi-closed low
smoke hood

2 Volume KVA 21000


3
Flue gas at furnace mouth m
3
/h 280000
Positive
pressure big bag
type dust
collector
Flue gas temperature at
furnace mouth
250-350
Resistance force of dust
collector
Pa 4800
Dust concentration g/Nm
3
3
4
Flue gas volume at furnace
top and distribution part
m
3
/h 50000
Negative
pressure pulse
bag type dust
collector
Flue gas temperature at
furnace top and distribution
part

<120
collector
Pa 3300
3
6
5
Flue gas volume of batching
system
m
3
/h 57000
Negative
pressure pulse
bag type dust
collector
Flue gas temperature of
batching system
<120
collector
Pa 3300
3
6

Flue gas composition of electric furnace %
N
2
CO
2
O
2
H
2
O
76-78 2-4 17.5-18.5 1.0-1.5

Ratio of dust with different particle size
1m 1~10m 10m
>92% 5% 3%

3.2 Design principle
The design of 21000KVA submerged arc furnace is based on the relevant policies,
stipulations about energy-saving, environmental protection, safety, industrial sanity
and seismic resistance, and the principle of advanced, practical and reliable
equipment.
21000KVA submerged arc furnace and furnace mouth gas cleaning use positive
pressure bag type dust removal system, furnace-top charging and distribution
equipment use negative pressure pulse bag type dust removal system, batching
system also use negative pressure pulse bag type dust removal system. These dust


removal methods are mature technologies. The positive pressure big bag dust
collector belong to unorganized emission, which reach the requirement of
environmental protection, it is lower than 5mg/m
3
, negative pressure pulse dust
collector belong to organized emission, which reach the requirement of
environmental protection, it is lower than 30mg/m
3

3.3 Design index
3.3.1 Flue gas capture ratio 99.5%
3.3.2 Service life of Glass fiber filter bag and polyester bag 1
3.3.3 Outlet dust emission concentration after cleaning of dust removal
system30mg/m
3
(organized emission); 5mg/m
3
( unorganized emission)
3.4 Work theory, parameters and model selection of dust collector
3.4.1 Dust removal system of electric furnace and furnace mouth
3.4.1.1 Work theory
The dusty high temperature flue gas of electric furnace flow into main flue pipeline
through chimney, and the flue gas at iron tapping notch of furnace too, then enter into
high efficient cyclone, it will forcibly remove big particles and part of harmful impurities,
the processed dusty gas enter into dust collector through intake tubes besides ash
hopper through main draught fan, part of dust deposit naturally in dust hopper, and
fine dust enter into filter bag following with air flow, and the dust is intercepted inside
filter bag, and gas is discharged through filter bag. The inner wall of filter bag thicken
gradually, which will increase the resistance force of filter bag, when the pressure
difference of dust collector reach the stipulated upper limit( usually 2000pa),
pneumatic switching valve start, and dust collector chambers stop filtering and clean
ash in turn. Due to sudden change of air flow direction, the filter bag change from
positive pressure condition to negative pressure, and at this time the filter bag change
shape and become sunken, the dust accumulated on inner wall of filter fall off into
dust hopper, when back-suction ash cleaning stop, filter bag change from negative
pressure to static condition, and at this time dust fall into dust hopper. This process is
called three conditions of ash cleaning. And this process repeat for 2-3 times, when
pressure difference of inlet and outlet of dust collector reach the lower limit value, the
procedure of ash cleaning automatically stop, and repeat the whole filtering process.


When the flue gas is higher than 280the mixer selector valve of dust removal
system automatically start, if the temperature is still higher than 280, the main
draught fan will automatically stop running and start discharge valve.

3.4.1.2
21000KVA electric furnace semi-closed low smoke hood
300-350
Chimney Main flue gas pipeline system
Iron tapping mouth flue gas 200-250
Adjustable centrifugal high efficient cyclone
Mixer selector valve 250
Main induced draught fan Positive pressure back-suction bag-type dust collector
Dust
Vehicle
3.4.1.3 Model selection and parameters
Pipeline
From two chimneys of furnace lead out two flues, and the pipelines use15005,the
wind speed is about 22m/s. The pipeline is strengthened with fixed ring every 2
meters and expansion joint every 30 meters to prevent elongation and twist of
pipeline.8 meters for pipeline support. Try to make sure pipeline camber R1.5
2D.There is installed with mixed wind valve before high efficient cyclone, and
thermocouple at the outlet end of draught fan to realize automatic temperature control,
when the temperature is higher than 280,the draught fan automatically start, and
automatically turn off when lower than 250.
Adjustable centrifugal high-efficient cyclone
Choose 2 sets adjustable centrifugal high-efficient cyclone, one set for one flue, and
one set can process 140000m
3
/h wind volume.
Main air blower
Two chimneys of electric furnace separately connect with one set of dust removal flue,
each flue is equipped with one induced draught fan, total 2 sets of draught fan.
Technical parameters of draught fan:


Model Y6-5115.2D
Flow capacity
140000m
3
/
h
Total
head
5200Pa Rotation rate 1480
Electric motor Y355L-4 Voltage 380V Power 315KW

Technical parameters of dust collector
Air flow 2140000m
3
/h Inlet temperature <250
Filter area 9893m
2

Dust concentration
at inlet
<3g/m
3

Filter wind speed 0.47 m/min
Dust concentration
at outlet
30mg/m
3

Number of
chamber
12 chambers
Specification of filter
bag
29210000mm
Number of filter
bag
1080 units Material of filter bag Graphite glass fiber
Resistance
power of
equipment
<2000Pa
Type of dust
collector
Positive pressure
back-suction big bag type
dust collector
Pneumatic system
As auxiliary equipment for running of dust collector, pneumatic system adopts air
compressor and gas storage tank as power source of cylinder working, and use steel
pipe as main gas circuit, connect every valves and cylinders with rubber tubes.
Technical parameters of pneumatic system
Compressed air
consumption
2m
3
/min
Work pressure of
compressed air
0.30.4Mpa
Gas storage tank
volume
2m
3

Design pressure of
gas storage tank
0.8Mpa
Electrical apparatus control system
This control system adopts high performance Siemens S200 programmable system,
it is designed and formulated according to the technical performance of TFC series
dust collector running. This control system can real-time monitor the running
condition, and detect, process data, adjust running state of equipment, it will keep
the best working state for dust collector.

3.4.2 Furnace-top charging and material distribution dust removal system
3.4.2.1 Work theory
On top of electric furnace, there are equipped with seal cover of circular material
distribution machine (1 pc), material blanking point gas collecting cover of charging
belt conveyor and distribution conveyor (total 2 pc). The dusty gas converge into main


pipeline through branch pipeline which equipped with manual regulating valve, then
enter into negative pressure pulse dust collector, and drawn out by main draught fan
and enter into exhaust funnel.
Part of dust sink in dust hopper of pulse dust collector, and the fine dust deposit on
surface of filter bag under effect of air current, the dust on outer surface of filter bag
gradually thicken, that will increase the resistance of filter bag. When the pressure
difference of inlet and outlet of dust collector reach the upper limit value(usually at
2000Pa),pneumatic switching valve automatically turn off, the branch chamber of
dust collector will proceed with pulse dust removal in turn. The deposited dust on
surface of filter bag will crack off and fall into dust hopper, this procedure will repeat
for 2-3 times, when pressure difference of dust collector reach the lower limit value,
the process of cleaning dust will automatically stop, at the same time store the whole
filter procedure, and continuously work like this repeatedly. The dust in hopper is
unloaded into truck by screw feeder, electric ash unloading valve through pipeline.
3.4.2.2 Technical flow diagram
Circular material distribution seal cover
Charging belt conveyor gas hood
Material distribution belt conveyor gas hood

Negative pressure pulse dust collector Draught fan and exhaust funnel
Dust

Vehicle
3.4.2.3 Model selection and parameters
Pipeline
The seal cover of circular material distribution machine is installed with one smoke
discharge pipe, and the pipeline use size of 7504, the wind speed is about18.9m/s.
The seal cover for head of charging belt conveyor is installed with one smoke
discharge pipe, the pipeline use size of 3254, the wind speed is 20m/s. The seal
cover for head of material distribution belt conveyor is installed with one smoke
discharge pipe, the pipeline use size of 3254, the wind speed is 20m/s. The above
branch pipelines separately enter into one main pipeline, the pipeline use size
of9504, the wind speed is about 19.6m/s. Each branch pipeline is equipped with
one manual regulating valve, 5 meters for pipeline support. Try to guarantee the


camber of pipeline R1.5~2D.

Negative pressure pulse dust collector
Technical parameters:
Processed air
volume
50000m
3
Filter area 882m
2
Inlet dust concentration <10g/Nm
3

Filter wind speed 0.95 m/min Outlet dust concentration 30mg/Nm
3

Number of chamber 4 chambers Filter bag specification 1304000mm
Number of filter bags 540 units Filter bag material Polyester
Number of
electro-magnetic
pulse valve

36
Electro-magnetic pulse valve
specification

DYM-89
Resistance force of
equipment
<2000Pa Type of dust collector
Negative pressure
pulse bag type dust
collector

Main draught fan
Model Y4-73 11D
Flow capacity 50000m
3
/h Total pressure 3800Pa Rotation rate 1450
Electric motor Y315S-4 Voltage 380V Power 90KW

Exhaust funnel
The outlet dynamic pressure of exhaust funnel is comparatively high, and the strong
airflow will cause loud noises, in order to reduce loss of dynamic pressure, the outlet
flow rate is designed at 7m/s, it adopts16004 pipeline, due to large diameter and
low flow rate, it will largely reduce exhaust noises.

Pneumatic system
Pneumatic system is the auxiliary equipment for running of negative pressure pulse
dust collector, this pneumatic system use air compressor and gas storage tank as
power source for cylinder working, and use steel pipe as main gas circuit, and it is
connected with each valve cylinder with plastic pipes.
Technical parameters:


Compressed air
consumption
4m
3
/min
Work pressure of
compressed air
0.30.4Mpa
Volume of gas
storage tank
3m
3

Design pressure of
gas storage tank
0.8Mpa

Electrical apparatus control system
This control system adopts high performance Siemens S200 programmable system,
it is designed and formulated according to the technical performance of TFC series
dust collector running. This control system can real-time monitor the running
condition, and detect, process data, adjust running state of equipment, it will keep
the best working state for dust collector.

3.4.3 Dust removal system of batching system
3.4.3.1 Work theory
The electric vibrating feeder under batching bin adopts sealed feeding type, and it is
equipped with gas hood for material falling point of discharging belt conveyor under
electric weighing hopper (8 units), gas hood for mixed materials belt conveyor
material falling point(1 unit).The dusty flue gas flow into main flue pipeline through
branch pipeline, then enter into negative pressure pulse dust collector, and exhausted
by main draught fan and discharge into exhaust funnel. Part of dust deposit in dust
hopper of negative pressure pulse dust collector, and fine dust enter into filter bag
following with air flow, and the dust is intercepted inside filter bag.
The inner wall of filter bag thicken gradually, which will increase the resistance force
of filter bag, when the pressure difference of dust collector reach the stipulated upper
limit( usually 2000pa), pneumatic switching valve start, and dust collector chambers
stop filtering and clean ash in turn. Due to sudden change of air flow direction, the
filter bag change from positive pressure condition to negative pressure, and at this
time the filter bag change shape and become sunken, the dust accumulated on inner
wall of filter fall off into dust hopper, when back-suction ash cleaning stop, filter bag
change from negative pressure to static condition, and at this time dust fall into dust
hopper. This process is called three conditions of ash cleaning. And this process
repeat for 2-3 times, when pressure difference of inlet and outlet of dust collector
reach the lower limit value, the procedure of ash cleani ng automatically stop, and
repeat the whole filtering process. The dust in hopper will unload into car through


screw feeder and electric ash discharge valve.
3.4.3.2 Technical flow diagram
Discharging belt conveyor gas hood
Mixed materials belt conveyor gas hood

Negative pressure pulse dust collector Draught fan and exhaust funnel
Dust

Vehicle
3.4.3.3 Equipment model selection
Pipeline
The head seal cover (8 units) for discharging belt conveyor under batching bin of
electric furnace is separately equipped with one exhaust pipe, the pipeline use size of
3254, the wind speed is about 20m/s. The head seal cover for mixed materials belt
conveyor is equipped with one exhaust pipe, the pipeline adopts size of 3254, the
wind speed is about 20m/s. The branch pipes separately enter into one main pipeline,
it adopts size of 10004, the wind speed is about 20m/s. Every branch pipeline is
equipped with one manual regulating valve, 5 meters of pipeline as support, try to
keep the camber of pipelineR1.52D.
Negative pressure pulse dust collector
Processed air capacity 57000m
3
Filter area 882m
2

Inlet dust
concentration
<10g/Nm
3

Filter wind speed 1.1 m/min
Outlet dust
concentration
30mg/Nm
3

Number of chamber 4 chambers
Specification of filter
bag
1304000mm
Number of filter bags 540 units Material of filter bag

Number of
electro-magnetic pulse
valve
36
Specification of
electro-magnetic
pulse valve
DYM-89
Resistance force <2000Pa Type of dust collector
Negative pulse
bag-type dust
collector

Main draught fan


Model Y4-73 11D
Flow rate 57000m
3
/h Total pressure 3800Pa Rotation rate 1450
Electric motor Y315S-4 Voltage 380V Power 90KW
Exhaust funnel
The outlet dynamic pressure of exhaust funnel is comparatively high, and the strong
airflow will cause loud noises, in order to reduce loss of dynamic pressure, the outlet
flow rate is designed at 6.2m/s, it adopts18004 pipeline, due to large diameter and
low flow rate, it will largely reduce exhaust noises
Pneumatic system
As auxiliary equipment for running of negative pressure pulse dust collector,
pneumatic system adopts air compressor and gas storage tank as power source of
cylinder working, and use steel pipe as main gas circuit, connect every valves and
cylinders with rubber tubes.
Technical parameters of pneumatic system:
Compressed air consumption 4Nm
3
/min
Work pressure of
compressed air
0.30.4Mpa
Gas storage tank volume 3m
3

Design pressure of
gas storage tank
0.8Mpa

5
th
, September,2014

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