Notes on

Electric Furnace Steel

making:

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Introduction:
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Electric arc furnaces (EAF) have become crucial in steelmaking recently due to
their adaptability to market demands. These furnaces, which can be mini steel
plants, produce various steel grades (long, flat, or mixed) from scrap and other
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materials like sponge iron or iron carbide. While scrap is the preferred material,
sponge iron and iron carbide are used due to scrap shortages and to reduce
tramp elements.
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Type of Electric furnaces:

EAFs work by forming an electric arc between electrodes and the metallic
charge, heating it through radiation. There are two types: alternating current
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(AC) and direct current (DC). In AC furnaces, current flows between electrodes
through the metallic charge, while in DC furnaces, it flows from a carbon
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electrode (the cathode) to an embedded anode. EAFs consume a lot of

electrical energy, making power cost and availability crucial for their

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 development. About 40 to 45% of the world's steel production comes from
EAFs.

Construction of AC Electric Arc Furnace:

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FIGURE: General view of an electric arc furnace in an axonometric projection:
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1 – bottom, 2 – water-cooled walls, 3 – roof, 4 – graphite electrodes, 5 – tubular

buses, 6 – exible cables, 7 – transformer, 8 – hydraulic oil tank. (Advertising
materials (corporate brochure) of the SMS group GmbH (formerly SMS Siemag
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AG) – with permission.)

1. Bottom: The base of the furnace where materials are loaded and melted.
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2. Water-cooled walls: Walls of the furnace that have water circulating

through them to prevent overheating.
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3. Roof: The top part of the furnace, which covers the melting area and can
be opened for charging materials.
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4. Graphite electrodes: Rods made of graphite (a type of carbon) that
conduct electricity and generate the heat needed to melt the materials.

5. Tubular buses: Tubes or pipes that carry electricity to the electrodes.

6. Flexible cables: Wires or cables that connect various parts of the

furnace, allowing flexibility in movement and operation.

7. Transformer: Equipment that changes the voltage of electricity, usually

reducing it from high voltage to a lower level suitable for the furnace.

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8. Hydraulic oil tank: A container holding hydraulic oil, which is used to

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operate machinery or systems within the furnace, such as tilting
mechanisms or electrode positioning.

Charging Materials:
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1. Steel Scrap: Primary raw material, making up 60 to 80% of the charge. It
consists of recycled steel materials.
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2. Sponge Iron and Pig Iron: Sometimes used to balance the chemical
composition of the charge.
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3. Slag Formers: Materials like limestone, fluorspar, sand, and quartzite

are added to create slag, which helps in refining the metal.
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4. Decarburization: Oxygen lancing is employed to remove carbon from

the molten metal.

5. Iron Ore: Added to enhance the iron content in the melt.

6. Deoxidizers: Ferro-manganese, ferrosilicon, or aluminum are added to

remove oxygen and other impurities.

7. Alloying Elements: Added to produce specific alloy steels with desired

properties.

Plant Layout:
1. Electric Furnace Area: This is where the main EAF(s) are located,
where the steelmaking process takes place.

2. Transport Facilities for Ladle: Infrastructure for moving ladles

containing molten metal to and from the furnace.

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3. Scrap Charging Area: Space designated for loading scrap materials
into the furnace.

4. Auxiliary Injection Facilities: Areas for injecting additional materials

like oxygen or carbon into the furnace for specific metallurgical processes.

5. Electrode Movement Mechanism: Infrastructure for raising,

lowering, and adjusting the position of the electrodes within the furnace.

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6. Charging of Raw Materials and Weighing System: Facilities for
charging various raw materials into the furnace and weighing them
accurately for precise control over the charge composition.

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7. Slag Disposal Area: Space for collecting and disposing of slag
produced during the steelmaking process.
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In an optimal layout, these facilities are arranged in a manner that ensures
efficient flow of materials and smooth operation of the steelmaking process
from input to output. Each area is designed to accommodate specific tasks
and equipment, facilitating the production of high-quality steel products.
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Arc Furnaces Operation:

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Charging:
1. Heavy and light scrap contained in large baskets are preheated through the
exit gas.

2. Burnt lime and spar are added to facilitate early slag formation.

3. Additional materials like iron ore or mill scale may be added for refining
during the meltdown period.

4. Some furnaces have continuous charging systems, and hot metal may also
be charged as needed.

Meltdown Period:

1. The furnace roof is swung off, and the furnace is charged with materials.

2. Electrodes are lowered and bored into the scrap. Initially, lower voltages
are selected to prevent excessive heat and damage to the roof and walls.

3. As the arc is shielded by scrap, the voltage is increased to form a molten

metal pool, reducing the meltdown period.

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4. During meltdown, silicon, manganese, and carbon oxidize, and oxidizing
and limy slag is produced, promoting dephosphorization.

5. Meltdown time is influenced by arc conditions (larger arcs require lower

current), and the depth of the bath (a deeper bath shortens the meltdown
period).

Refining:

1. Refining processes continue alongside melting.

2. Phosphorus removal must be completed before temperature rise and

carbon boil.

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3. Single oxidizing slag practice is used when sulfur removal is unnecessary.

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For removal of both phosphorus and sulfur, double slag practice is
employed.

4. In double slag practice, oxidizing slag is removed, and reducing slag is

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formed after deoxidation with ferrosilicon, ferromanganese, or aluminum.
Reducing slag helps prevent loss of alloying elements.

5. Once the desired bath chemistry and temperature are achieved, the heat is
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deoxidized and finished for tapping.

Comparison between Electric Arc Furnace (EAF)

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steelmaking and Oxygen steelmaking:

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Source of Energy:
- EAF: Utilizes electric energy along with chemical energy from materials like
hot metal and directly reduced iron.

- Oxygen Steelmaking: Relies primarily on chemical energy. It's an

autogenous process, meaning it's self-sustaining once initiated.

Iron-Containing Raw Material:

- EAF: Uses a combination of hot metal, directly reduced iron, and scrap in
proportions determined by practice.

- Oxygen Steelmaking: Typically utilizes hot metal along with a smaller

proportion of scrap, usually around 20-30%.

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Operating Procedure - EAF:
- Oxygen lancing is employed to promote decarburization, facilitate scrap
melting, and induce post-combustion.

- Slag foaming is induced to shield the refractory lining from the intense heat
of the arc.

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- Carbon injection may be utilized to induce foamy slag practice, enhancing

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refining efficiency.

Operating Procedure - Oxygen Steelmaking:

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- Oxygen supply is continuously fed into the process to refine hot metal into

- A three-phase dispersion of slag, metal, and gas is formed to accelerate

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refining rates.

While both EAF and Oxygen steelmaking processes aim to produce steel, they
differ in their energy sources, raw material composition, and operating
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procedures. EAF relies on a combination of electric and chemical energy and

utilizes a mix of iron-containing materials, while Oxygen steelmaking primarily
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relies on chemical energy and primarily uses hot metal with a smaller
proportion of scrap. Operating procedures in EAF involve oxygen lancing, slag
foaming, and carbon injection, whereas Oxygen steelmaking focuses on
continuous oxygen supply and the formation of a three-phase dispersion for
refining.

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