50 Ton Ultra-high Power Electric arc furnace Introduction
The 50-ton ultra-high power electric arc furnace (50TUPH EAF) adopts ultra-high power, high impedance technology, bottom tapping technology (ETB), furnace wall oxygen oil burner and furnace door carbon-oxygen gun technology. It mainly produces alloy steel, bearing steel, spring steel, gear steel, etc.
The 50T steelmaking electric arc furnace has simple furnace temperature control and small equipment footprint. It is suitable for smelting high-quality alloy steel, etc.
The 50 ton ultra-high power electric arc furnace has a smelting cycle of 70 minutes, an average steel output of 55 tons, and an average power factor of 0.85.
50 Ton Ultra-high Power Electric Arc Furnace Introduction
The 50-ton ultra-high power electric arc furnace (50TUPH EAF) adopts ultra-high power, high impedance technology, bottom tapping technology (ETB), furnace wall oxygen oil burner and furnace door carbon-oxygen gun technology. It mainly produces alloy steel, bearing steel, spring steel, gear steel, etc.
The steel electric arc furnace electrode arc generates high temperature to smelt scrap metal. An arc is formed between the charged material and the electrode. When the gas discharge forms an arc, the energy is very concentrated, and the temperature of the arc area is above 3000 ℃. The heat generated by the arc melts the scrap, and the electric arc furnace can effectively remove impurities such as sulfur and phosphorus.
The steelmaking electric arc furnace consists of three parts (lower furnace body, upper furnace body and furnace roof), which can be tilted hydraulically. The lower container, upper container and the top are lined with refractory materials. The outside and top of the container are usually composed of water-cooled steel structures.
The 50 ton ultra-high power electric arc furnace has simple furnace temperature control and small equipment footprint. It is suitable for smelting high-quality alloy steel, etc.
The 50 ton ultra-high power electric arc furnace has a smelting cycle of 70 minutes, an average steel output of 55 tons, and an average power factor of 0.85.
Main Application of 30 Ton Electric Arc Furnace
Used to produce alloy steel
bearing steel, spring steel
gear steel, etc.
50 Ton Ultra-high Power Electric Arc Furnace Equipment Features
1. The mechanical structure of the 50t ultra-high power electric arc furnace adopts an integral large platform rail type, and the layout is an elevated layout.
2. The steel electric arc furnace body is composed of an upper furnace shell, a lower furnace shell, a furnace door mechanism, a bottom tapping mechanism (EBT furnace), a water-cooled furnace wall, an inlet and return water stop valve, and a metal hose.
3. The active furnace shell structure is adopted, that is, the furnace shell is separated from the tilting cradle, and the upper and lower furnace shells can be separated.
4. The upper furnace shell is composed of a water-cooled tubular frame and a water-cooled furnace wall. The bottom of the water-cooled furnace wall is 350mm away from the slag surface to increase the life of the furnace lining.
5. The lower furnace shell is welded with a 25mm thick steel plate, and its bottom is a conical structure.
6. The comprehensive energy utilization technology is adopted, equipped with a furnace door carbon oxygen gun and a furnace wall cluster oxygen gun. The secondary combustion of CO escaping from the molten pool effectively makes full use of the chemical energy in the flue gas to reduce power consumption and produce foam slag.
7. High impedance technology is adopted to increase the secondary voltage, realize long arc melting, and the arc is relatively stable. The impact on the power grid is reduced, the short-circuit system current is smaller, the energy consumption and electrode consumption are reduced, and the effective input of electricity is improved.
50 Ton Ultra-high Power Electric Arc Furnace Equipment Composition
The 50 ton ultra-high power electric arc furnace equipment includes furnace body, tilting platform, molten steel transport vehicle, water-cooled furnace cover and smoke collection device, furnace cover rotating lifting mechanism, copper-steel composite conductive cross arm and electrode lifting device, secondary short network, hydraulic system, water cooling system, argon blowing system, ladle furnace transformer, high voltage system, low voltage electrical control and PLC automatic control system.
Sanrui Ultra-high Power EAF Technical Advantages
Low Power Consumption and Cost Reduction
The high current system of the steelmaking electric arc furnace uses pure copper as the conductive medium, and the entire loop resistance is small. Taking full account of the skin effect when current passes through conductors, the cross arm adopts a box-shaped copper-steel composite plate structure, which can effectively reduce resistance and heat generation. Reasonable high-current system layout makes various current impedances smaller.
EAF Equipment Operation is More Stable and Smelting is Safer
The entire hydraulic drive is equipped with an accumulator, which stabilizes the pressure of the hydraulic system and makes the equipment run more stably. At the same time, in emergencies such as power outages, the equipment can continue to perform unfinished operations, which improves the safety of smelting.
Electrode Consumption Reduced
The anti-electrode breakage system can effectively reduce the chance of electrode breakage during the smelting process. In particular, avoiding electrode breakage during the scrap melting process is equivalent to saving an entire furnace of molten steel and reducing economic losses.
The Equipment is Simple to Operate and Easy to Use
Electrical automation control adopts human-machine interface, which simulates the form of real furnace body and is easy to operate. Batching, loading, smelting and tapping can all be operated on the computer.
High Arc Starting Efficiency
Using a new type of electrode adjustment system, the steel electric arc furnace electrode lifting control breaks the previous single signal return control technology and adopts multi-signal collection and PLC signal comparison technology to increase the electrode arc starting speed and avoid long-term effects on the electric arc furnace during the arc starting process. Upper level power grid system.
Diversification of Dust Removal Systems
The dust removal systems we are equipped with are diversified and can be equipped with different forms of dust removal equipment according to the environmental protection requirements of different countries.
50 Ton Ultra-high Power Electric Arc Furnace Parameters
EAF 50 Ton Ultra-high Power Main Equipment Parameters
| Nominal Capacity | 50t |
| Average Tapping | 55t (6-9t steel remaining) |
| Maximum Tapping | 60t |
| Inner Diameter of Furnace Shell | 5200mm |
| Operation Form | Left Operation or Right Operation |
| Transformer Rated Capacity | 28MVA |
| Transformer Primary Voltage | 35KV |
| Frequency | 50Hz |
| Transformer Secondary Voltage | 436-380-184V |
| 436-380V | |
| 380-184V | |
| Voltage Regulation | Class 19 Electric On-load Voltage Regulation |
| Transformer Secondary Rated Current | 42.543KA |
| Transformer Cooling Form | Strong Oil Circulating Water Cooling |
| Three-phase Impedance Unbalance Factor | ≤5% |
| Graphite Electrode Diameter | 500mm （High Power Graphite Electrodes） |
| Electrode Distribution Circle Diameter | 1150±50mm |
| Conductive Cross Arm | Copper-steel Composite Conductive Cross Arm, Large-section Water-cooled Cable |
| Electrode Rising Speed | 6m/min（Automatic） 9m/min（Manual） |
| Electrode Descending Speed | 4m/min（Automatic） 6m/min（Manual） |
| Electrode Lift Maximum Stroke | 3800mm |
| Tilt Angle | Eccentric Bottom Tapping 20°, normal 12~15 |
| Maximum Angle of Slag Discharge is 15° | |
| Tapping Method | Eccentric Bottom |
| Furnace Cover Lift Height | 500mm |
| Furnace Cover Rotation Angle | ~70° |
| Slag Door Dimensions (W X H) | 1100 X 900mm |
| Ladle | 50t ~ 70t |
| Hydraulic System Working Pressure | 12MPa |
| Hydraulic Medium | Water—Ethylene Glycol |
| Electrode Lift Control Method | Electro-hydraulic Proportional Valve (Import) |
| System Filtration Precision | ＜10μ （Level 4） |
| Cooling Water Outlet Temperature | ≤55℃ |
| Cooling Water Inlet Temperature | ≤35℃ |
| Cooling Water Consumption | ~850m³/h |
50 Ton Ultra-high Power Electric Arc Furnace Transformer Main Parameters
| Parameter name | Requirements | Parameter name | Requirements |
| Transformer model | HSSPZ-35000/35 | Operating conditions | Indoor |
| Rated capacity | 35MVA (long term +20%) | Cooling method | OFWF |
| Secondary rated voltage | 670～520V | Voltage regulation method | On-load voltage regulation (ABB switch) |
| Secondary rated current | 38.906KA | Connection group number | Yd11 |
| Frequency/phase number | 50Hz/3 | Inlet and outlet method | Top inlet and side outlet |
| Impedance voltage drop | 7.60% | Insulation level | LI200AC85/AC5 |
Scope of 50 Ton Ultra-high Power Electric Arc Furnace Supply
Furnace body: furnace shell, furnace door mechanism, tapping spout mechanism
Furnace roof: tubular water-cooled furnace roof, refractory center roof (this is a drawing produced by the seller, made by the buyer)
Furnace croof lifting and rotating mechanism: furnace cover lifting mechanism (cylinder, chain, gear, etc.), (Γ frame), rotating mechanism, rotating locking mechanism
Tilting mechanism: arc-shaped frame, base, tilting hydraulic cylinder
Electrode cross arm and lifting mechanism: electrode support arm, electrode clamping device, lifting mechanism
Short network: stainless steel bracket, compensator, water-cooled cable, stainless steel bracket, water-cooled conductive copper tube
Cooling water system: water inlet distributor, return water tank, pressure gauge, thermometer, valve
Hydraulic system: motor, pump, filter, tank, control valve, accumulator
High-voltage power supply system: isolation switch, voltage transformer, vacuum circuit breaker, current transformer, lightning arrester, etc.
Electric furnace transformer
Low voltage electrical system
Low-voltage power cabinet, PLC cabinet, main operating console, furnace front operating console, hydraulic operating box, control sensor, limit switch, etc.
Automation control system: Siemens PLC
Electric Arc Furnace Steelmaking Process
01
The basic process of electric arc furnace steelmaking includes slag removal, metal charging, power supply, melting, oxidation, reduction refining and tapping. Depending on the characteristics of the type of steel being smelted, there are different operating methods. The smelting process mainly consists of three phases: melting, oxidation, and reduction.
02
With the continuous development of steel electric arc furnace technology, the electric arc furnace steelmaking process has also undergone great changes. During the melting period, auxiliary energy is used to accelerate melting, such as injection of oil-oxygen, natural gas-oxygen or pulverized coal-oxygen. The melting time of each furnace is shortened by 15 ~20min, power consumption can be reduced by 50~60kWh/t;
03
During the oxidation period, measures such as early dephosphorization, intensive oxygen use, powder spraying to create foam slag, and rapid temperature rise can reduce the amount of oxidative decarburization from 0.3% in traditional processes to 0.1% to 0.15%, thus shortening the oxidation period by 50%. above.
04
In the reduction period, diffusion deoxidation in the traditional process is mainly replaced by precipitation deoxidation, and diffusion deoxidation is supplemented. White slag or carbide slag needs to be produced. Each furnace smelting takes 3 to 4 hours, and the power consumption is as high as 600 to 700kWh/t. Not only can the expected refining effect be achieved, but the steel quality is guaranteed and the reduction time can be shortened by more than 60%.
05
While improving the quality of molten steel, the process improvement has also increased productivity by about 20%, reduced power consumption by 10% to 15%, and reduced electrode consumption by about 8%, achieving considerable economic benefits.
Sanrui Electric Arc Furnace Technology Optimization
After optimizing steelmaking electric arc furnace technology, Sanrui has achieved the best balance between raw materials, scrap preheating, energy conservation and environmental protection, smelting process control, automation control, smelting cycle and production capacity. The electric arc furnace inputs electric energy into the electric arc steelmaking furnace through graphite electrodes, and uses the arc between the electrode end and the charge as the heat source for steelmaking.
The steel electric arc furnace uses electric energy as the heat source and can adjust the atmosphere in the furnace, which is extremely beneficial for melting steel types that contain more easily oxidized elements. Utilize high-temperature flue gas from electric furnaces to preheat raw materials through technology and equipment to achieve high efficiency, energy saving, environmental protection and high yield.
With the improvement of China electric arc furnace equipment and smelting technology, and the development of the electric power industry, the cost of electric furnace steel continues to decrease. Nowadays, electric furnaces are not only used to produce alloy steel, but also to produce ordinary carbon steel and iron ore concentrate pellets.
Services Provided by Sanrui
1. As China electric arc furnace manufacturer, Sanrui can provide foundation layout and layout drawings
2. Sanrui will send engineers to your factory to install and debug the machine, providing trustworthy after-sales service.
3. Sanrui provides operation and maintenance personnel training, and the smelting equipment is easy to operate and maintain.
4. Competitive price and excellent quality
5. Low investment, high production efficiency and high rate of return
6. Smelting equipment has stable performance and safe production
7. Steelmaking electric arc furnace can be customized according to different needs
8. Production capacity can be adjusted according to customer requirements
9. Environmentally friendly, low energy consumption
Sanrui is well experience in designing, manufacturing, installing, debugging and commissioning steelmaking process equipment.
Sanrui provides engineering consulting, R&D, design, equipment supply, system integration and software compilation, construction, installation, debugging, project management, technical services and training, production guidance, operation and maintenance, spare parts supply and other comprehensive engineering and technical services.
Send us your project details to buy electric arc furnace and our engineering team will design an 50 ton ultra-high power electric arc furnace steelmaking production line solution according to your needs.
Related Products
Customized metallurgical machinery and equipment range: Electric Arc Furnace, Submerged Arc Furnace, LF Refining Furnace, Vacuum Furnace, Induction Furnace, Dust Remove System, Water Treatment Equipment, etc. Providing the most advanced equipment integration services, metallurgical equipment can be customized according to different needs of customers, and production capacity can be adjusted according to customer requirements.
Electric Arc Furnace Steel Making
Electric arc furnace steel making is a steelmaking method that uses the thermal effect of electric arc to heat the charge for melting.
Ultra-high Power Electric Arc Furnace
Ultra-high power electric arc furnace mainly changes the arc characteristics of high voltage and long arc to the arc characteristics of high current, low voltage and short arc
The 5 ton electric arc furnace for steel-making is a special purpose equipment that makes ordinary steel, quality carbon steel, alloy steel and non-corrosive steel with electric arc as heat source and scrap steel (iron) as raw material.
30 Ton electric arc furnace is used for steelmaking short process smelting, using 100% scrap steel or scrap steel + molten iron (pig iron), or scrap steel + sponge iron (DRI) as raw materials for steelmaking.
30 Ton AC Electric Arc Furnace
The 30-ton AC electric arc furnace is used to melt scrap steel to produce steel. Electrical energy is used to melt scrap steel. An arc forms between the charged material and the electrode.
Electric arc furnaces are used to melt scrap steel for steel production. Electrical energy is used to melt scrap steel. An arc forms between the charged material and the electrode. The heat generated by the arc melts the scrap.
DC electric arc furnace is an electric arc furnace supplying electric energy with DC power supply. There is only one electrode on the top of the DC arc furnace, which is the negative electrode, and the bottom electrode is the positive electrode.
15-ton electric arc furnace is used for the short-process steelmaking process, using 100% scrap steel or scrap steel + molten iron (pig iron), or scrap steel + sponge iron (DRI) as raw materials for steelmaking.
Our Completed Projects
Sanrui metallurgy furnace equipment integration services are submerged arc furnaces and electric arc furnaces. Sanrui metallurgy furnaces are manufactured using cutting-edge technology to ensure an efficient, high-quality melting process. These furnaces are capable of melting a variety of materials, including steel, iron and alloys, ferroalloys (such as ferrotungsten, high carbon ferromanganese, high carbon ferrosilicon, high carbon ferrochromium, ferronickel alloys) and industrial silicon, calcium carbide, corundum, yellow phosphorus, etc. with precise temperature control and minimal energy consumption. By using Sanrui metallurgy furnace equipments, metallurgical companies can increase productivity and reduce production costs, ultimately increasing profitability.
Sanrui is well experience in design, manufacturing, installation, commissioning of steelmaking furnace process equipment. Send us your project details inquiry and our team of engineers will design a metallurgical furnace equipment system solution from A to Z based on your needs.
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