Basic Structure and Operation of Submerged Arc Furnaces

The submerged arc furnace represents a sophisticated type of electric furnace, integrating various components including the furnace body, furnace transformer, high-current conductors (short network), electrode system, feeding system, cooling system, high- and low-voltage power distribution systems, monitoring and automation systems, iron slag handling system, and smoke exhaust and dust removal system. This complex electrometallurgical equipment is designed for efficient and controlled smelting processes.

In operation, the high-voltage electrical energy supplied by the power grid is transformed into low-voltage, high-current electricity through a specialized transformer tailored for the submerged arc furnace. This current is then conveyed to the electrodes via high-current conductors and introduced into the furnace through carbon electrodes. Around these electrodes, electrical adhesion and arc heat are generated at the electrode extremities, effectively converting electrical energy into heat energy. This transformation creates a high-temperature reaction zone within the furnace body, facilitating the reduction reaction of metal oxide ores.

Typically, carbon reducing agents such as coke are employed in the process. Continuous addition of coke and reduced metal oxide ore raw materials sustains the reaction within the zone. As a result, liquid products accumulate in the molten pool. Periodically, the furnace outlet is opened to discharge the molten metal, which is subsequently refined into alloy products. The slag is either quenched or utilized after pouring, depending on the specific requirements.

Submerged arc furnaces are primarily categorized into round and rectangular types. Given the substantial amount of furnace gas (flue gas) produced during smelting and production, round submerged arc furnaces are further classified into high smoke hood open furnaces, semi-closed furnaces, and closed furnaces. The furnace body can be either fixed or rotatable in these configurations. In contrast, rectangular submerged arc furnaces generally feature a closed structure with a stationary furnace body.

Historically, open furnaces equipped with high smoke hoods posed significant environmental concerns due to severe pollution, high energy consumption, and non-compliance with labor and health regulations. Consequently, these open furnace designs have been gradually phased out in favor of more environmentally friendly and energy-efficient alternatives. Modern submerged arc furnaces now prioritize closed or semi-closed designs to minimize emissions, enhance energy efficiency, and ensure compliance with stringent environmental and safety standards.

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