Analysis of Electrical Energy Consumption in a Novel Direct …
Submerged arc furnace is a smelting device with high efficiency but huge electricity consumption. A novel structure of direct current (DC) submerged arc furnace is investigated for ferrochrome production to save electric energy. For this purpose, a three-dimensional transient multi-physics model is developed to simulate the furnace.
Metals | Free Full-Text | Nickel Laterite Smelting Processes …
Submerged arc furnace (SAF) and the traditional rotary kiln-electric furnace (RKEF) processes have also been used for low-grade ferro-nickel production. In general, these processes yield low-grade ferro-nickel containing Ni in …
Energy Balance Diagram of the Rotary Kiln (R/K)-Electric Furnace …
The main parameters affecting energy and electrode consumption in smelting reduction of Greek nickeliferous laterites in submerged arc electric furnaces (E/F) were investigated.
Analysis of Electrical Energy Consumption in a Novel Direct …
A novel structure of direct current (DC) submerged arc furnace is investigated for ferrochrome production to save electric energy. For this purpose, a three …
Yang Yu's research works | Northeastern University …
Yang Yu's 9 research works with 32 citations and 1,121 reads, including: Simulation of Ferrochrome Settling Behavior in a Submerged Arc Furnace Using a Multiphysics and Multiphase Model
Analysis of Electrical Energy Consumption in a Novel …
furnace (SPSF) system and rotary kiln-electric furnace (RKEF) system.[4] In recent years, improving the smelting efficiency and energy saving of AC submerged arc furnaces has been a major industrial concern. Usually, AC submerged arc furnace has been studied using thermodynamic analysis,[5,6] experimental mea-surements,[7–9] and simulations.
Simulation-based life cycle assessment of ferrochrome …
To gain insights, environmental impacts of ferrochrome smelting technologies were estimated using simulation-based life cycle assessment. Two leading technologies: (1) Steel Belt Sintering-Submerged Electric Arc Furnace (SBS-SAF), and (2) Rotary Kiln-Submerged Electric Arc Furnace (RK-SAF) were investigated.
Material and energy flows in rotary kiln-electric furnace …
Submerged arc furnace is a smelting device with high efficiency but huge electricity consumption. A novel structure of direct current (DC) submerged arc furnace …
The Submerged Arc Furnace (SAF): State-of-the-Art Metal
The submerged electric arc furnace (SAF) has proven a versatile unit in numerous metallurgical applications for more than a century. Countless innovations have made this furnace type become the most commonly used furnace for increased metal recoveries and slag-cleaning operations.
Processes | Free Full-Text | Process Improvements for Direct Reduced
The majority of DRI is melted and refined in the electric arc furnace with different process conditions compared to the melting of steel scrap due to its raw material composition being rather different. ... P. Optimal control of accretion growth and quality of sponge iron in a coal-fired rotary kiln at Tata Sponge, India. In Proceedings of the ...
Nickel-iron Alloy Refining Furnace Manufacturers and …
The rotary kiln - submerged arc furnace smelting process is widely used both domestically and internationally for the production of nickel iron alloys with high nickel content.
Material and energy flows in rotary kiln-electric furnace …
Among these methods, the rotary kiln-electric furnace (RKEF) process has the advantages of yielding high nickel/iron grade from crude ferronickel products, less …
Material and energy flows in rotary kiln-electric furnace smelting …
Liu et al. [19] developed mass and energy balances to assess the dryer, rotary kiln, and electric arc furnaces. The rotary kiln furnace showed potential for waste heat recovery from the discharged ...
Simulation of Ferrochrome Settling Behavior in a Submerged Arc Furnace …
The ferrochrome settling behavior significantly affects the smelting performance of a submerged arc furnace. This paper presents a three-dimensional (3D) transient mathematical model simulating the complex multiphase flow and thermochemical phenomena inside an industrial furnace. Via the model, the smelting phenomena are …
Nickel laterite rotary kiln-electric furnace plant of the future
Rotary kiln-electric furnace (RKEF) smelting is currently the world-wide mainstreaming process for ferronickel production from nickeliferous laterite ore, in spite of the high power consumption ...
Simulation of Ferrochrome Settling Behavior in a …
systems, i.e., the rotary kiln-electric furnace system (RKEF) and the sintering-preheating-submerged arc furnace system (SPSF).[3] In either system, submerged arc furnaces (SAF) plays a vital role in ferrochrome production.[4] SAF is an energy-intensive reactor for producing ferronickel, ferromanganese, ferrochrome, and other ferroalloys.
Material and energy flows in rotary kiln-electric furnace smelting …
The rotary kiln-electric furnace process is the one of the most widely adopted technological process for ferronickel smelting production. A schematic of the RKEF process with rotary dryer, rotary kiln and electric furnace is shown in Fig. 1. As depicted, the RKFF process involves three main processes: the dehydration process in rotary …
Energy Consumption and Greenhouse Gas Emissions of High …
This work presents a process model developed based on mass and energy conservation to assess high carbon ferrochrome production from cradle to gate through four supply routes: (1) a conventional submerged arc furnace (SAF), (2) a closed submerged arc furnace with preheating (CSAF+PH), (3) a closed submerged arc furnace with …
The development of a CFD model of a submerged arc furnace …
Feasibility is established for the reduction of phosphate ores in a rotary kiln, avoiding electric submerged arc furnace technology. This represents a totally new approach to phosphoric acid. … Expand
Improving the rotary kiln-electric furnace process for …
Improving the rotary kiln-electric furnace process ... allurgical processes are pelletizing and submerged injection ... reduction-smelting in an arc furnace. NiO in the slag was less
Evaluation and synergy of material and energy in the …
The smelting technologies including rotary kiln-electric furnace and steel belt sintering-submerged arc furnace, have developed during the past 30 years [6]. The steel belt sintering-submerged arc furnace is more promising because of the lower energy consumption and higher productivity [7].
(PDF) Improving the rotary kiln-electric furnace process for
The primary pyrometallurgical route to produce ferronickel from laterite nickel ores is the Rotary Kiln-Electric Furnace (RKEF) process. In the RKEF process, minerals undergo calcination and ...
Smelting and Selective Reduction of Limonitic Laterite Ore
These technologies include the Rotary Kiln-Electric Furnace (RK-EF) process [19, 20], Vaniukov process [21, 22], direct reduction [23,24,25], Submerged Electric Arc Furnace, Rotary Hearth Furnace (RHF), and smelting in a Blast Furnace . The smelting of laterite ore using the Mini Blast Furnace (MBF) is widely utilized in …
The history and development of the
The process utilized co-current rotary kilns for prereduction, and submerged-arc furnaces for the production of pig iron with approximately 1.15% vanadium. Because of various technical challenges that the submerged-arc furnaces experienced over the years, a decision was taken in 2004 to convert the furnaces to open slag bath (OSB) operation, …
Production of FeNi by the rotary kiln-electric furnace process at Hyuga
Semantic Scholar extracted view of "Production of FeNi by the rotary kiln-electric furnace process at Hyuga Smelter" by T. Ogura et al.
Pragmatic analysis of the electric submerged arc furnace …
The principal nickel production route comprises the reductive smelting of calcine in electric submerged arc furnaces (EAFs); calcine is the yield of reductive roasting of nickelferrous lateritic ores in rotary kiln furnaces [3–5].
Furnace VS Kiln: Definition and Difference
Types of Electric Furnaces: (a) direct arc, (b) indirect arc, and (c) induction. Kiln Definition A kiln is a thermally insulated chamber, a type of oven that produces temperatures sufficient to complete some process, such as …
High Carbon Ferrochrome Technology
The most common production technology utilized is submerged arc smelting in AC furnaces, although open arc smelting in DC furnaces is becoming increasingly common. ... Two leading technologies: (1) Steel Belt Sintering-Submerged Electric Arc Furnace (SBS-SAF), and (2) Rotary Kiln-Submerged Electric Arc Furnace (RK-SAF) …
Technology Innovations in the Smelting of Chromite Ore
pelletized chromite ores in a rotary kiln using energy obtained from coal pulverization and hot gases generated from the closed submerged arc furnace. It also provides high recoveries of ferrochrome and utilizes low cost reductant sources such as anthracite. Keywords: Chromite ore, Ferrochrome, Submerged arc furnace, Outokumpo, Premuse 1.
Pre-Heating Manganese Ore in a Pilot-Scale Rotary Kiln
The actual carbon consumption is not optimal, there is an overconsumption linked to an incomplete decomposition and prereduction of manganese oxides inside the submerged arc furnace (SAF), where the reactions kinetics can be difficult to control.
Energy Balance Diagram of the Rotary Kiln (R/K)-Electric …
The main parameters affecting energy and electrode consumption in smelting reduction of Greek nickeliferous laterites in submerged arc electric furnaces (E/F) were investigated.
Enhancing Rotary Kiln-Electric Furnace Process of Saprolitic …
How to reduce the energy consumption of the rotary kiln-electric furnace (RKEF) process has become an important issue for the stainless steel industry. The aim of this study is to reduce the energy consumption of ferronickel production from saprolite nickel laterite in the RKEF process. The effects of the slag binary basicity, FeO content, and …
Outotec SAF Smelting
The Outotec Submerged Arc Furnace (SAF) is a closed-type, environmentally friendly, and energy-efficient solution for ... preheating kiln and efficient electric power control of the submerged arc furnace. Expert project planning and execution Our experienced planning, engineering, procurement,
submerged arc furnace: Topics by Science.gov
Submerged-arc furnace technology is applied in the primary production of ferroalloys. ... 1970: "The rotary kiln with two plasma guns and arc transfer" by Marc Foëx; 1984: "The plasma furnace" by Electricité de France (EDF) at …
Improving the rotary kiln-electric furnace process for …
The primary pyrometallurgical route to produce ferronickel from laterite nickel ores is the Rotary Kiln-Electric Furnace (RKEF) process. In the RKEF process, minerals …
Exergy assessment of a rotary kiln-electric furnace smelting …
Semantic Scholar extracted view of "Exergy assessment of a rotary kiln-electric furnace smelting of ferronickel alloy" by Wenjie Rong et al.