Simulation of Ferrochrome Production in Submerged Arc Furnaces for Optimisation of Specific Energy Consumption

Abstract

An off-line simulator, "FERALSIM", has been developed for simulating the production of ferrochromium in submerged-arc furnaces. The "thermochemical module" of the simulator predicts the quality of metal that can be produced for given raw material conditions and the specific energy consumption. This module can be used for adjusting the charge compositions to achieve the desired quality of alloy at an optimum specific energy consumption. The "temperature profile" module maps out the temperatures at various locations in the furnace. This module can be used for minimising heat loss through the walls, bottom and top of the furnace. The "power supply" module depicts the power and current densities spatially inside the furnace for different electrode configurations and applied voltage. This module is useful for maintaining a balance in power supply and for ensuring that the furnace volume is utilised efficiently. A module on "kinetics of reduction" assists the operator in under-standing the degree of reduction at various levels inside the furnace and the time required for complete reduction. The utilisation of the simulator is demonstrated with examples.