Introduction to the Low/Micro-Carbon Ferrochrome Furnace

Introduction to the Low/Micro-Carbon Ferrochrome Furnace

Low and micro-carbon ferrochrome furnaces (including facilities for producing re-melted ferrochrome) are essential for manufacturing key ferroalloys with diverse applications:

Primary Applications:

1.  Steel Alloying Agent: Used in high-carbon ball bearing steel, tool steel, and high-speed steel to enhance hardenability, wear resistance, and hardness.

2.  Cast Iron Additive: Improves the wear resistance, hardness, and heat resistance of cast iron.

3.  Raw Material for Other Ferroalloys: Serves as a chromium source for producing silicon-chromium alloys and for the slagless production of medium, low, and micro-carbon ferrochrome.

4.  Feedstock for Electrolytic Metal Chromium.

5.  Raw Material for Stainless Steel: Used in oxygen-blown stainless steel production processes.

Equipment and Structural Features:

The furnace is of an arc-type tilting-frame design, with tapping performed via a hydraulic tilting mechanism.

   Safety and Stability: When returned to the horizontal position, the furnace body is secured by two horizontal supports on the rear arc frame. This design prevents tipping accidents in the event of hydraulic system failure.

   Control System: The electrode lifting mechanism employs a hydraulic proportional valve speed regulator controlled by a Siemens programmable logic controller (PLC), ensuring simple, reliable, and precise operation.

   Electrode Mechanism: Electrode movement is driven by hydraulic cylinders, providing flexible, safe, and reliable control.

   Tilting System: Furnace tilting is achieved through a hydraulic transmission system using an integrated block valve manifold. The hydraulic station features two plunger pumps (one operational, one standby) and an accumulator for pressure maintenance.

   Electrical System & Buswork: Utilizes six large-section water-cooled cables, conductive arms, flexible compensators, copper busbars, and an energy-optimized short-network arranged in a triangular configuration. The short-network impedance is designed to be ≤ 0.5 + j2.3 mΩ, with three-phase impedance unbalance ≤ 5%.

   Conductive Arm and Clamp: The conductive arm is fabricated from a novel copper-steel composite plate, offering excellent high-temperature resistance. The electrode clamps are forged from chromium-copper alloy and utilize stainless steel straps for clamping, providing high force, easy adjustment, reliable operation, resistance to arcing, and extended service life.

   Instrumentation & Monitoring:

       High-side metering (active/reactive energy) and primary/secondary overcurrent relay signals for furnace power consumption are routed to the low-voltage control room for measurement and monitoring.

       Secondary voltage indicator lights and voltmeters are installed both in the control room and on the furnace platform for local observation.

   Cooling Water System: Incorporates pressure and temperature monitoring with alarms. All welds in water-cooled zones are shielded from direct arc radiation. The system features a low-inlet, high-outlet water flow design.

   Dust Extraction & Charging: The furnace is equipped with a semi-closed hood connected to a dust removal system via an exhaust outlet for effective fume control. The charging port includes a feed rate control valve.

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