Analysis of Energy Efficiency Optimization Processes for Full Scrap Steel Smelting in Consteel Electric Arc Furnace
I. Features of Consteel Electric Arc Furnace
The Consteel electric arc furnace is a novel type of electric arc furnace characterized by a "short process, green, and energy-saving" approach. It is designed to support the smelting of a mixture of "scrap steel + hot metal" and has relatively loose requirements for raw materials. The process integrates several advanced technologies, including continuous feeding, scrap preheating, ultra-high power supply, long arc foamy slag, water-cooled furnace walls, water-cooled furnace covers, conductive cross-arms, and off-bottom tapping. These features significantly reduce overall energy consumption.
II. Energy Efficiency Optimization Processes for Full Scrap Steel Smelting
Optimization Directions
Optimization of Lance Parameters: By adjusting the amount of carbon powder sprayed and blowing in compressed air, the problem of slag accumulation at the lance nozzle is avoided. The oxygen lance process parameters are optimized to control the oxygen supply flow rate and prevent over-oxidation of foamy slag.
Temperature Coordination and Dual-Lance Operation: During the smelting process, temperature coordination is strictly controlled to form the optimal oxygen lance inclination and stir the molten pool to homogenize the steel temperature.
Optimization of Power and Oxygen Supply Matching: The power supply and oxygen supply are integrated for consideration. Based on the energy requirements of different smelting stages, the tasks of chemical energy and electrical energy supply are determined to achieve the best match between electricity and oxygen.
Specific Optimization Measures
Scrap Preheating and Continuous Feeding: Utilizing scrap preheating and continuous feeding technologies to reduce electrical energy consumption and shorten the smelting time.
High-Impedance and Energy-Saving Design: Implementing high-impedance designs to improve the efficiency of electrical energy utilization and reduce electrical consumption.
Refining Slag System and Temperature Control: Optimizing the refining slag system by adjusting the amounts of lime, pre-melted slag, alloy, and aluminum wire added to control the alkalinity and temperature of the refining slag.
III. Practical Application Effects
Cost and Energy Efficiency Advantages
Reduced Production Costs: By optimizing the process, the electrical and oxygen consumption per ton of steel are reduced, and the smelting cycle is shortened.
Resource Recycling and Environmental Protection: Using slag steel as raw material, the process achieves the resource utilization of metallurgical solid waste and reduces environmental pollution.
Comprehensive Economic Benefits: In an industrial application trial at a steel mill, the optimized process shortened the electrification time to 22.95 minutes, the smelting cycle to 36.35 minutes, reduced electrical consumption to 154.78 kW·h/t, and oxygen consumption to 33.56 m³/t.
Technological Innovation and Patent Achievements
Authorized Patents and Enterprise Standards: A new smelting process based on "slag steel + (0~30%) desulfurized slag iron" has been developed, resulting in multiple authorized patents and the formation of enterprise standards.
Deep Desulfurization Treatment: For high-sulfur steel (S: 0.04%-0.1%), an efficient desulfurization process has been developed to ensure that the sulfur content in the steel after LF refining is below 0.01%.
IV. Future Development Directions
Further Reduction of Energy Consumption: By continuously optimizing the power and oxygen supply systems, further reduce the overall energy consumption of the electric arc furnace.
Expansion of Application Scope: Promote this process to more steel enterprises, especially in areas with abundant scrap steel resources.
Intelligent and Digital Transformation: Combine intelligent systems to monitor and optimize the smelting process in real-time, improving production efficiency.
The energy efficiency optimization processes for full scrap steel smelting in Consteel electric arc furnaces have significant advantages in reducing costs, improving resource utilization, and reducing environmental pollution. They provide important support for the green and low-carbon development of the steel industry.
