Analysis of Dynamic Conditions in Electric Arc Furnace Steelmaking  

Analysis of Dynamic Conditions in Electric Arc Furnace Steelmaking

Insufficient kinetic conditions for metallurgical reactions within the molten bath have long been a key technical challenge in electric arc furnace (EAF) steelmaking.

The limited stirring intensity of the EAF bath is fundamentally related to the inherent characteristics of the furnace design. Traditional EAFs use scrap steel as the primary raw material and rely predominantly on electrical energy, supplemented by chemical energy, to produce qualified molten steel. Consequently, EAF design typically features a relatively large diameter and a shallow bath. For instance, the height-to-diameter ratio of a 100-ton EAF is only about 53% of that of a converter of equivalent capacity.

Generally, a greater height-to-diameter ratio allows for a higher oxygen supply intensity. Furthermore, practical constraints in EAF operation—such as the need to manage scrap melting and slag flow through the furnace door—further restrict the achievable stirring intensity. As a result, the bath stirring strength in an EAF is typically only 10% to 20% of that achievable in a converter.

Stirring intensity can be quantified by molten steel flow velocity. Numerical simulations of molten steel flow in a 100-ton EAF reveal an average flow velocity of approximately 0.06 m/s. In contrast, the average flow velocity in a 100-ton converter is about 0.31 m/s. This significant difference underscores the markedly weaker stirring conditions within the EAF bath.

This disparity in dynamics manifests clearly in actual production. The smelting consumption and production cost gaps between EAF and converter steelmaking are pronounced. Key endpoint parameters—such as the carbon-oxygen product ([C]·[O]), dissolved oxygen content, and slag FeO content—are important indicators of bath stirring intensity and have a substantial impact on final product quality.

Data from multiple advanced steel plants comparing endpoint conditions for EAF and converter heats show that EAF steelmaking typically results in a higher average carbon-oxygen product (around 0.0032) and a significantly higher final slag FeO content (exceeding 22.00%) compared to converter steelmaking.

In summary, the low stirring intensity of the electric arc furnace bath, constrained by furnace geometry and process characteristics, presents a fundamental limitation that hinders further technological advancement in EAF steelmaking efficiency and quality control.

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