More efficient operation of arc furnaces with continuous scrap charging

The basic concepts of the Consteel process are analyzed. In that process, scrap is continuously charged in the liquid bath on a conveyer. The scrap is heated to 150?C250°C on the conveyer by the gases leaving the furnace. While continuous charging has clear benefits, the low efficiency of scrap heating means that Consteel furnaces cannot match the productivity and energy efficiency of modern arc furnaces. The melting rate of the scrap is 1.4 times greater in (100?C350)-t arc furnaces than in comparable Consteel furnaces, while the power consumption is 40 kW-h/t less. Unidirectional heating of the scrap on the Consteel conveyer by powerful gas-oxygen burners to a mean mass temperature of 800°C is proposed. The new 120-t TDSP fuel-arc smelting furnace, with equal power of the arc and the burners, reduces power consumption to 200 kW-h/t and reduces the smelting time to 32 min.