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SUBMERGED-ARC FURNACES AND ELECTRIC SMELTERS

SUBMERGED-ARC FURNACES AND ELECTRIC SMELTERS

Submerged-Arc Furnaces and Electric SmeltersSMS SIEMAG

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For more than 100 years it has been our businessand tradition to work out solutions in the field of submerged-arc furnaces and electric smelters. Ourtechnology assures the success of our customers inthe ferroalloy and non-ferrous metal industries. Ourplants are characterized by state-of-the-art designand high-end manufacture. References from all over the world demonstrate the economic successwhich is achieved through stable and safe operation.

SMS SIEMAG AG

Our company is a world-class manufacturer of metal-lurgical plant and rolling mill equipment. First-rate,high-performance products along with a customer-focused approach featuring comprehensive servicesform the basis of our company’s good reputation.Equally convincing are our concepts and plantsbecause they provide state-of-the-art technology andcost effectiveness as well as quality and reliability.

As a global leader in industrial plant engineering,SMS Siemag supplies an end-to-end product rangeto the steel, aluminum, copper, ferroalloy and non-ferrous industries, extending from systems for theproduction of hot metal to all areas of steelmaking,continuous casting, rolling mill technology, as well ashot and cold strip finishing and heat-treating equip-ment.

SOLUTIONS FORYOUR SUCCESSSOLUTIONS FORYOUR SUCCESS

STEELMAKING AND CONTINUOUS

CASTING TECHNOLOGY DIVISION

The department for submerged-arc furnace (SAF) andelectric smelting technology is represented by theSteelmaking and Continuous Casting Technology Divi-sion. We cover the full range of products for ferroal-loys, nonferrous metals, special applications and iron-making.

In line with SMS Siemag’s well-known customer-ori-ented approach, the division supplies turnkey solu-tions, from single units to integrated plants, includingtheir control and optimization systems as well as anynecessary engineering services and on-site assistance.Our extensive reference list demonstrates that prof-itability goes hand in hand with ecologically balancedsolutions and reliable and safe operation.

CONTENTS

2 3 Solutions for your success

4 5 Process know-how, metallurgical background

6 7 Economic success with SAF and electric smelter technology

8 9 SAF and electric smelter design features

10 13 SAF and electric smelter design highlights

14 15 Electrical aspects

16 17 Automation and instrumentationGas cleaning, dedusting systems and water cooling systems

18 19 Our services

20 21 Application for ferroalloys and SI-metal

22 23 Application for non-ferrous metals

24 25 Special processes

26 27 Ancillary equipmentFerroalloy refining

28 29 Innovations for the futureReferences

30 31 SAF and electric smelters at a glance

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The information provided in this brochure contains a general descrip-tion of the performance characteristics of the products concerned. The actual products may not always have these characteristics asdescribed and, in particular, these may change as a result of furtherdevelopments of the products. The provision of this information is notintended to have and will not have legal effect. An obligation to deliverproducts having particular characteristics shall only exist if expresslyagreed in the terms of the contract.

OUR MISSION

We design and build complete state-of-the-art sub-merged-arc furnaces, as well as integrated plantsand components that will produce products of thehighest quality, consistency and reliability. Theplants are designed and built in such a manner thatquick ramp-up and safe, long-lasting operationare assured.

The plants are designed for operation in an environ-mentally responsible and economical manner. Weachieve our set project goals in teamwork, hand-in-hand with our customers. After the completion ofeach job we remain in close contact with the cus-tomers.


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EXPERIENCE AND INNOVATION

We are pioneers in terms of innovative SAF and elec-tric smelting technology. Almost 700 references havebeen installed worldwide. These include completeplants, furnaces and core equipment.

The first furnaces were commissioned in 1906. By 1913, the first submerged-arc furnace with sixelectrodes was operating successfully. In 1950, the first furnaces exceeded the 40,000 kVA powerrating benchmark.

During the last decade more than 50 different prod-ucts have been processed with SAF and electricsmelting technology for the ferroalloy, non-ferrousmetals, ironmaking and special applications indus-tries. Each individual process requires extensive anddetailed process knowledge. Our experts have creat-ed the foundation for the correct design and opera-tion of each furnace.

TEAMWORK AND COOPERATION

It is our philosophy to keep good contacts with thecustomer after contractual obligations have been ful-filled. We are constantly discussing new technologi-cal challenges and common day-by-day tasks withnumerous companies, universities and research anddevelopment institutes. The optimizing of technologi-cal solutions together with the customer is ourstrength.

DATA ACQUISITION

Plant data from running operations are analyzed inorder to optimize the processes in existing facilitiesand to use them in future developments.

PROCESS KNOW-HOW,PROCESS KNOW-HOW,metallurgical background

Furnace roof of DC smelter.

SAF in the early fifties.

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DATA EVALUATION

By means of online assistance, our customers areable to make use of a joint working group which provides the know-how for adapting and optimizingthe process sequences.

DATA ARCHIVE

We maintain a data archive of those plants in produc-tive operation. These data provide helpful processparameters that can be integrated as know-how intocurrent projects.

An extensive database is availableInnovative process development

Slag tapping.

Slag depleting.

Test furnace.

Ferro alloy furnace.

DECISIVE ADVANTAGES


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SUCCESS

Satisfied customers confirm the reliability and high perform-ance of our plants. Our team assist the customers with alltheir requirements concerning the plant through the inten-sive care that we provide on-site during the planning, engi-neering, erection and commissioning phases. We take pridein the plants erected by us, which guarantee long-lastingadded value for our customers.

Rapid start-up curve

Faithfulness to deadlines goes without saying, but SMS Siemag try to do even better: to achieve a rapidlyincreasing start-up curve before the appointed date.

Feasibility studies

Feasibility studies are also part of our range of services.They often constitute the basis for the project financing.

Flexible financing options

Reliable equipment and good plant engineering are key factors in the financing of a project.

Return on investment

The nature and scope of our customers investment are crucial for the success of the project. Quick start-up of production and reliable, flexible work sequences at lowoperating costs ensure that their investment will be paidback within a very short time.

Rapid ramp-up curveSustained, low-maintenance operationRapid return on investment

ECONOMIC SUCCESSECONOMIC SUCCESSwith SAF and electric smelter technology

Success story 1RDME, France: Turnkey job, completion 12 months afterorder effective date.

Success story 2Enami, Chile: Turnkey job, completion after 14 months,design capacity was reached after 2 weeks.

DECISIVE ADVANTAGES

Commissioning of SABAYEK Ferro Alloy Plant / Saudi Arabia

Furnace No. 2 – FeSi 75

Furnace No. 1 – SiMn

Furnace No. 3 – Si-Metal

Furnace No. 4 – Si-Metal

1 2 3 4 5 6 7 8 9 10 11 12

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Success story 3Eramet, New Caledonia: furnace modification, while doubling the furnace capacity. 99 days for dismantling, erection and start up.

Success story 4Sabayek, Saudi Arabia: 4 furnaces erected andcommissioned in 2 years.


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A WIDE RANGE OF DESIGN

SERVICES

We have designed a large variety of sub-merged-arc furnaces and electric smelters,adapted to suit the individual requirementsof the customer. This great variety of ourdesigns is described below. Many fur-naces, many features: Our design calcula-tion suits the specific requirements of eachindividual process. We have successfullyworked out technical solutions to copewith the harsh operating environment.These developments are integrated intoconventional solutions, providing reliableand safe equipment.

SAF GENERAL DESIGN

FEATURES

Open designClosed designSpecial design

SAF AND ELECTRIC SMELTERDESIGN FEATURESSAF AND ELECTRIC SMELTERDESIGN FEATURES

MAJOR CUSTOMERS BENEFITS:

The furnaces designed by us meet all of the respective processrequirementsReliable and safe operation

DECISIVE ADVANTAGES

Furnace gas hood

RoundOpen/closable designHigh/low-temperature designChain/plate curtainRaising/sliding doorsAir/fume injection systemsWater-cooled steel structureInert atmosphere option

Suspended electrode column.

Lower part of e-column.

Electrode columnsSelf-baking electrodes (Soederberg)Graphite/prebaked electrodesExtrusion electrodes/compoundelectrodes Hollow electrode system (HES)Suspended/supported designDC-electrode column (patented)Below/above-roof maintenanceClamping position below/above theroof Intensive water coolingCooling shields and protection ringVarious seal features

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Furnace charging

Manual/automaticHot/cold chargingLiquid chargingBatch/continuous feedingMix charging through HES (hollowelectrode system)

FeNb furnace.

Furnace shell

Round/rectangular design Flat/curved bottom Cylindrical/conical shape Stationary/rotating shell Open/covered bath operation Changeable/tiltable Sidewall, bottom cooling Water/air cooling

Si-metal furnace.

Furnace shell cover – closed roof

Round/rectangular shape Cylindrical/conical shape Water-cooled steel structure Suspended brick roof/cast roof Flat/arched shape

Slag cleaning furnace.Si/FeSi furnace.

High-current supply system

Copper bus tubes/barsParallel/triangle arrangementWater/air cooled flexiblesFlexibles inside/outside of the hoodInterleaved/parallel arrangement Forged contact clamps

Submerged-Arc-Furnaces and Electric SmeltersSMS SIEMAG

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SAF AND ELECTRIC SMELTERDESIGN HIGHLIGHTSSAF AND ELECTRIC SMELTERDESIGN HIGHLIGHTS

ELECTRODE COLUMN SYSTEMS

The new generation of the electrode column guaran-tees enhanced stability of the hot-side componentsat minimized electrical losses. High durability underunfavorable conditions, low maintenance and easyoperator guidance are outstanding features of thistechnology.

MAIN FEATURES

Protection ring made from non-magnetic steel or forged copper for energy savingFail-safe hydraulically actuated electrode holdingand slipping device Durable contact-clamps for even electrode bakingprovide highest possible energy transfer to theelectrodeReliable electrical insulation up to 2,000 voltsElectrode welding/nippling under operating voltageElectrode slipping under full-load currentEfficient column sealing prevents the escape offurnace gasesLittle maintenance, easy to handleCompact units, minimized space requirementsCentralized hydraulic system/supplyWear resistance ensures long service life

STRUCTURAL FURNACE PARTS

with minimized electrical losses

The design of our structural furnace parts minimizeselectrical losses caused by alternating magneticfields. Components are checked by FEM calcula-tions. The new design features allow up to 5% elec-tric power to be saved.

ELECTRODES

The choice of the right electrodes is a function of the economic and metallurgical aspects and of theprocess sequence.

DC-electrode system

Conventional DC-furnaces applies an electrode arm.Our new patented DC-electrode system allows slip-ping under power, which maximizes the productivityin comparison with conventional technology.

Pre-baked electrode systems

Pre-baked electrodes are available in several gradesand sizes. They can be used for all applications how-ever are mainly used for the production of siliconmetal.

Self-baking (Soederberg) electrode

systems

Self-baking Soederberg electrodes have lower oper-ating costs and are usually utilized in furnaces withhigher capacities in ferroalloy, ironmaking, non-fer-rous metals and CaC2 production.

Hollow electrode systems

Hollow electrode systems are used for charging under-sized grains into the furnace in order to lower produc-tion costs and increase the recycling rate and thereforeenhance the process efficiency. 17 systems have beeninstalled in various plants for calcium carbide and FeCr.

Lower part e-column.


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COOLING CONCEPTS

All different cooling concepts ensure a stable, safeand long furnace campaign. An ideal balance existsbetween safe operation and long furnace life at mini-mized heat losses from the cooling system.

OPTIMIZED COOLING CONCEPTS

Furnace roof:

Spray cooling Closed-circuit duct cooling

Shell wall:

Rinse cooling Spray coolingChamber cooling Duct coolingCu-strip coolingTailor-made cooling elements (fingers, plates) for locally stressed areasWater-cooled tapholes

Shell bottom:

Air coolingSpray coolingDuct cooling

SPECIAL FURNACE-SHELL

SIDEWALL COOLING

SMS Siemag has developed a special cooling systemfor SAF sidewalls. The patented system consists ofcopper strips in the furnace shell sidewall. The coolingducts are located outside the furnace shell to preventinfiltration of water into the furnace. The system isoperating successfully in a two 99 MVA rectangularfurnaces at Eramet-SLN in New Caledonia. Whilemaintaining the furnace dimensions, the capacity ofthese FeNi furnaces was able to be increased from 33 MW to 75 MW by a parallel change-over to extraheat input via electric arc. The system will also sup-plied to the worlds largest furnaces (120 MVA) atCVRD/MOP and Anglo American Barro Alto, Brazil.

TAPHOLE DESIGN

The tapholes can be supplied in conventional design.For applications with higher stress requirements,water-cooled units are available for metal, matteand slag tapping.

REFRACTORY CONCEPTS

The refractory material and lining concepts are steadily improved. An optimized balance betweencooling principle and lining concept ensures long,safe and efficient operation. Some furnaces showimpressive campaigns of approx.15-20 years with the same lining. Heat transfer calculations (includingcontrol systems) provide a sound basis for thisdesign.

RELIABLE FAILSAFE HYDRAULIC

SYSTEMS

Failsafe hydraulic systems provide smooth and reli-able furnace operation and allow quick movements,even of heavy electrode columns. All hydraulicallyoperated components, i.e. electrode columns, fur-nace doors, charging chute gates, stack closures,etc. are supplied by one central hydraulic pressure-generating unit. The system has been continuouslyoptimized and is failsafe and maintenance-friendly.

The best available design High-quality manufactureAll components are based on our experience and know-howContinuous further development

DECISIVE ADVANTAGES

SAF AND ELECTRIC SMELTERDESIGN HIGHLIGHTSSAF AND ELECTRIC SMELTERDESIGN HIGHLIGHTS

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Stripe cooling concept(horizontal option).

Side wall cooling systemof FeNb furnace.

Electrode interior.

SAF under construction.

Contact clamps.

Rotating gear.


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The submerged-arc furnace today is the mostwidely used technology for the melting of non-ferrous metals.

SMS Siemag has experience in AC and DC applica-tions. Depending on the environmental conditionsand the selected process, we offer our customersAC or DC solutions that are supported by our experi-ence and know-how.

AC TECHNOLOGY

Metallurgical reactions in the submerged-arc furnacetake place at high temperatures. The required electri-cal energy is taken from the supply mains and fedinto the reaction zone via a variable-ratio transformer,the high-current lines and the electrodes.

The transformer, high current lines and electrodesform an electrical circuit together with the reactionzone. Various arrangements and types of connec-tions for the transformer are applied, depending onthe furnace capacity and requirements.

A new feature is the use of an electric arc forcapacity increase, for example in FeNi furnaces. Thearc is stabilized by means of thyristor technology.

ELECTRICAL ASPECTSELECTRICAL ASPECTS

AC option 1Three-phase variable-ratio transformer withlow-inductance high-current line routingand delta connection at the electrodesfor round or rectangular furnace shell.

AC option 2Three single-phase variable-ratio transform-ers arranged symmetrically around the furnace, with delta connection at the elec-trodes for round or rectangular furnaceshell.

AC option 3Three single-phase transformers with fixedratio; one preceding three-phase variable-ratio transformer and delta connectionfor round furnace shell.

AC option 4Three single-phase variable-ratio transform-ers for 6-electrode furnaces, with inlineelectrodes for rectangular furnace shell.

AC option 5Three single-phase variable-ratio transform-ers for 6-electrode furnaces, electrodearranged in two parallel lines for rectangularfurnace shell.

Reliable failsafe operationLong-lasting solutionExtensive AC and DC experience

DECISIVE ADVANTAGES

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DC TECHNOLOGY

Our company developed the DC technology in theseventies especially for electric steel plants whichwere placed in locations with poorer electrical gridconditions. DC technology, in combination with newcontrol systems, can reduce flicker by up to 70% incomparison with conventional AC technology.

DC furnaces are usually also characterized by a lowerelectrode consumption. Furthermore, this technologycan be designed in such a way that stronger stirringand better fuming rates in the furnace are achieved.

In 1993 SMS Siemag put the first DC electric arc fur-nace into operation in Belgium. This furnace was atthat time the most powerful DC EAF with 95 MVAand 85 t tapping weight. Late in 1994 the second DCEAF of this configuration with 155 t tapping weightand a 140 MVA transformer rating was successfullycommissioned in Luxembourg. Meanwhile, morethan 80 DC EAF’s have been built or are under con-struction.

In 2002 we supplied a DC submerged-arc furnacewith billet-type anodes for titanium oxide slag toKumba in South Africa. Since 2004 we have alsobeen offering our clients the conductive bottomanode design which has already proven its successat several customers, for example at NamkawaSands, South Africa (50 MVA, TiO2 slag), Samancor(56 MVA, FeCr) and ARM Platinum (previously Avmin)(60 MVA, cobalt). In 2009 we shall commissioninganother furnace for the production of titanium oxideslag at our customer Xinli, PR China.

The latest development is an electrode column allow-ing the nippling and slipping of the electrode underfull power.

High current supply lines.

Conductive hearth of DC-furnace.


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Automation is the key item in submerged-arcfurnace technology and includes:

Control systemInstrumentationAdvanced process control.

Besides the normal instrumentation, SMS Siemaghas developed measuring systems for:

Metal and slag level in the furnaceContinuous measurement of metal temperature in the runnerCharging levelGas analysis systemsFurnace pressure regulating systems

Stable and safe operation with 100% controlover the process:

Off-line kinetic modeLoad optimization and calculation modelCharging modelFinal mass and energy balancesSAF parameter calculationLining temperature monitoringHearth erosion monitoringData harmonizationOperator guidance

AUTOMATIONINSTRUMENTATIONAUTOMATION andINSTRUMENTATION

Automation and monitoring ensure reliableoperation at low energy consumption andlow wear

Control room.

DECISIVE ADVANTAGES

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Our technological know-how and our efficiencyensure a complete coverage of the entire sub-merged-arc furnace plant including the downstreamand upstream units. Especially for closed furnaces,the off-gas treatment is one of the key componentsbecause the furnace pressure is a critical parameterand needs to be controlled within a narrow range.We have developed accurate systems which allowthis tight furnace control at highly efficient cleaningrates.

SMS Siemag provides complete solutions forwater treatment. Basically three principles of off-gascleaning systems are provided:

Dry system:

Bag filter of suction/pressure/reversed-air typeFilter dust compacting for Si-metal and FeSi-furnaces, optional

Wet system:

DisintegratorVenturi

Electrostatic filters:

Electrostatic precipitatorsSince 1972 more than 60 dry cleaning filter systems have been installed.This is equivalent to approx. 1300 MVA total SAFpower rating.Since 1972 more than 30 wet cleaning systemshave been installed.

GAS CLEANING, DEDUSTINGSYSTEMS AND WATER COOLING SYSTEMS

GAS CLEANING, DEDUSTINGSYSTEMS AND WATER COOLINGSYSTEMS

Clean operation in an environmentallyresponsible manner

Cooling water plant.

Heat recovery.

Dry dedusting system.

DECISIVE ADVANTAGES


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Planning

Sound planning is the key to extensive investigationinto the feasibility and reliability of the technical and economic concepts. Planning includes tailor-madedesign for each specific customer. Hand-in-hand withour clients and project partners we elaborate thebest specific concept, e.g. the best location, themost economical design and layout, high-qualitymachinery and equipment and optimized operationconcepts, with a view to achieving a saleable productat market value.

Engineering

Experienced staff with know-how in respect ofprocess, metallurgy, engineering, design and con-struction as well as commercial and economic issues are available for the project handling.

Implementation

We consider cooperation with worldwide partnersand the utilization of the knowledge and experienceof local companies to be an essential approach to the completion of a successful project. We seek andfind the technically most viable solution at the mostfavorable cost. Our staff is available worldwide fordirect contact and for project support.

OUR SERVICESOUR SERVICES

Experienced staff for planning, engineering,procurement, commissioning and trainingTeamworkIn-depth knowledge on specific local conditionsExtensive brown field experience

DECISIVE ADVANTAGES

We also offer services and engineering activitiescovering not only modernization projects but alsoturnkey new plant, as well as coordination, consult-ing and supervision. Qualified commissioning engi-neers, process experts and metallurgists accompanythe projects during the cold and hot commissioningphases.

Training

Our customers’ operating personnel are trained atour head office, in the plant itself and at similarinstallations. SMS Siemag’s specialists are also avail-able for instruction and assistance during the com-missioning phase.

We can perform studies in the following subjectareas on your behalf:

De-bottlenecking study, process modeling studies(including material handling, furnace process,electrical/mechanical elements, gas cleaning/dedusting, metal/alloy and slag handling)Use of refractories / environmental situationControl system modernizationFurnace power managementFeasibility studies / project studiesFinite Element Analysis (FEA)

We can develop solutions in the following areas onyour behalf:

Maintenance planning / product optimizationFurnace dimensioning (vessel + roof)Minimization of operating costsNew cooling systems for enhancing capacity, lifetime and safetyFurnace modelingSimulation of plant logistics

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Installation

SMS Siemag provides experienced, highly-qualifiedsite supervisors. The site installation includes erection/installation manuals, erection/installationsequence, scheduling, site inspection and warehouseorganization. We deal with the coordination of logis-tics, transportation and storage, setup of inventoriesand of a reporting system which provides a clearoverview of the completeness and proper delivery of the equipment.

Brownfield sites

Work on brown field installations is a challenging job, both from the engineering and the installationpoint of view. SMS Siemag was involved in morethan 50 revamps which establish a solid base for professional solutions.


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APPLICATION FOR FERROALLOYSAND SI-METALAPPLICATION FOR FERROALLOYSAND SI-METAL

SI-METAL

Depending on the charged raw materials, Si-metalgrades can reach a purity of >98 %. The larger fur-naces are placed on a rotating gear, providing opti-mum operation.

FERRO-SILICON

The ferro-silicon grades produced in a submerged-arcfurnace have Si contents of 43 to 96 %. Grades withmore than 96 % Si are known as silicon metal. Thefurnaces are characterized by encapsulated electrodecolumns with hydraulic control, contact clamp tight-ening operation and short, low-inductance powersupply lines. Silicon metal production units generallyutilize prebaked electrodes. We also provide specialextrusion/compound electrode systems for Si-metalproduction, to reduce operating costs.

Ferro-silicon metal specification:

Possible range standardFeSi 40 – 50 % Si FeSi45FeSi 72 – 78 % Si FeSi75FeSi 85 – 96 % Si FeSi90

FERRO-MANGANESE

AND SILICO-MANGANESE

Ferro-manganese is usually available on the marketas high-carbon (6 to 8% C), medium-carbon (1 to 4%C) and low -carbon (<0.4% C) ferro-manganese prod-ucts. Alloys with high Si contents (15 to 20%) areknown as silico-manganese. High-carbon ferro-man-ganese and silico-manganese are produced in openor closed furnaces with a stationary shell.

Ferro-manganese specification

H.C. FeMn 6 – 8 % CM.C. FeMn 0.5 – 2 % C

L.C. FeMn < 0.5 % CM.C. SiMn 15 – 25 % Si, 0.5 – 2 % CL.C. SiMn 25 – 35 % Si, < 0.5 % C

FERRO-CHROME AND

SILICO-CHROME

High-carbon ferro-chrome is produced with carboncontents of 4 to 8 % and is usually used in AOD converters for the production of alloy steel grades.Due to environmental restrictions, ferro-chrome iscustomarily produced in closed stationary furnaces.Medium-carbon chrome alloys (0.5 to 2 %) and low-carbon FeCr (<0.5 %) are produced in combinedprocess stages involving special slag metallurgy,with the objective of attaining high chrome yields.

Ferro-chrome specification

H.C. FeCr 4 – 8 % CM.C. FeCr 1 – 2 % CL.C. FeCr < 0,5 % CSiCr 20 – 45 % Si

FERRO-NICKEL

Ferro-nickel is produced in submerged-arc furnacesby chemical reduction of nickel ores. Ferro-nickelfurnaces are closed stationary-type furnaces. Usually,round furnaces are used for smaller and mediumquantities, whereas large capacities are produced inrectangular furnaces.

Ferro-nickel specification

FeNi 15 – 30% Ni

SPECIAL ALLOYS

Special alloys are usually produced in small units.These alloys include ferro-tungsten, ferro-vanadium,ferro-tantalum, ferro-niobium.

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Market leader in SAF technology for ferroalloy productionExtensive process know-how for reliableequipmentHigh efficiency at low energy consumption

PLANT HIGHLIGHTS

Basco, Kazakhstan

2 x 27 MVA Si-metal

CVRD/MOP, Brazil

2 x 120 MVA FeNi

Anglo American Barro Alto, Brazil

2 x 114 MVA FeNi

Votorantim, Brazil

63 MVA FeNi

Yermakovsky, Kazakhstan

2 x 80 MVA FeCr

RDME, France

102 MVA SiMn/FeMn

SKW Becancour, Canada

47 MVA FeSi, 2 x 36 MVA Si-metal

Tulcea, Rumania

2 x 33 MVA FeMn, 43 MVA FeCr,2 x 55 MVA FeSi

Zunyi, China

2 x 50 MVA FeSi, 1 x 30 MVA FeM

Gulf Ferro Alloys Comp., Saudi Arabia

4x27 MVA SiMn, FeMn, FeSi, Si-metal

Eramet SLN, New Caledonia

3x48 MVA FeNi

Jindal Stainless India

2x60 MVA FeCr

Minera Loma de Niquel, Venezuela

2 x 45 MVA FeNi

Eti Krom A.S., Turkey

2 x 30 MVA FeCr (revamp)

Bluestar, Yongdeng, China

2 x 25.5 MVA (revamp) and 2 x 27 MVA Si-metal

Eramet SLN, New Caledonia

2 x 99 MVA FeNi (furnace revamps with copper cooling)

DECISIVE ADVANTAGES

SELECTED REFERENCES

From top: 1. Ferro-silicon furnace, 2. and 3. FeNi furnaces, 4. FeSi/Si-metal.

NICKEL MATTE

AND COPPER MATTE

The production of copper matte and nickel mattefrom primary smelter and converter slags in electricfurnaces is similar to the ferro-nickel process. Thefurnaces are closed, stationary-type furnaces. Usual-ly, round furnaces are used for smaller to mediumsize quantities, whereas large capacities are pro-duced in rectangular furnaces.

SLAG CLEANING FURNACES

We provide several submerged-arc furnace units forslag cleaning. To date, more than 30 plants havebeen installed worldwide. The slag is either liquid-charged into the furnace or can be cold-charged insolid form via conventional feeding systems. Theshape of rectangular furnaces provides good settlingconditions, resulting in high recovery rates.

Various applications are possible:Copper (e.g. from Teniente converter, ISA smelter,Pierce Smith converter, Outokumpu flash smelter,Noranda converter, reverts)NickelCobaltLead (e.g. from Kivcet process) and secondary leadZincTin and secondary tinPlatinumPalladiumPGM

LEAD AND ZINC

Submerged-arc furnaces are suitable for the recyclingof flue-dust from the steel industry (e.g. EAF dust)and for the recycling of Pb/Zn-containing slag fromshaft-furnace-based zinc/lead production plants. Zinc fuming and slag cleaning furnaces can also beoffered with DC power supply.


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APPLICATION FORNON-FERROUS METALSAPPLICATION FORNON-FERROUS METALS

Major customers benefits:

Market leader in SAF technology for non-ferrous applicationExtensive process know-how for reliableequipmentHigh process efficiency at low energy level

DECISIVE ADVANTAGES

Two in-line slagcleaning concept.

Enami, Chile Cu-slagcleaning furnace.

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Norddeutsche Affinerie, Germany

9 MVA copper slag cleaning8 MVA copper/lead recycling

Atlantic Copper, Spain

11 MVA copper slag cleaning

Enami, Chile

9, 8 and 11 MVA copper slag cleaning

Codelco, Chile


MCM, Zambia

12 MVA rectangular, copper slag cleaning

Norilsk, Russia

4 x 18 MVA Ni/Cu-slag cleaning

SAMIN, Italy and Cominco, Canada

9 MVA Pb-slag cleaning (Kivcet process)

ENAF, Bolivia

3.3 MVA Sn-slag cleaning

Kazzink, Kazakhstan


Liquid charging to SAF.

Charging of rectangularfurnace at MCM.

SELECTED REFERENCES

Rectangular design forslag cleaning.


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SPECIAL PROCESSESSPECIAL PROCESSES

CaC2 plantCyanamid, Canada.

TiO2-Slag tapping of a DC furnace.

The submerged-arc furnace and electric-smelters aresuitable units for the efficient recycling of the follow-ing: Steel mill wastes, ferroalloy wastes and platinumgroup metal (PGM) wastes Catalysts (from the auto-motive and oil industries) Flue ashes from powerplants depending on the material charged, conven-tional AC furnaces or DC furnaces are used.

REFRACTORIES AND MINERALS

The principle of the SAF allows the melting of miner-als with high fusion temperature. Therefore, the fur-naces are also utilized in various fields for refractoryand mineral production. The following products canbe produced with SAF:

Corundum (Al2O3)Sintered mineralsFused magnesiaMineral woolBasalt/Mineral woolRefractories

SPECIAL FURNACES

We also deliver tailor-made test furnaces in labora -tory or pilot scale.

CaC2, CaSi

Calcium carbide (CaC2) is used for the production ofacetylene and calcium cyanamide. Calcium carbideand calcium silica are also used as desulfurizationagents in the steel industry.

TiO2 slag

Titanium slag furnaces are similar to ironmaking fur-naces. Major products are TiO2-rich slag and pig ironas valuable “by-products”. The most recent installa-tions are all based on DC-technology.

RECYCLING

The SAF converts revert ashes to non-hazardous,non-leachable slag. The furnaces recycle steel-millwaste such as mill scale and dust, blast-furnace fluedust and sludge into a ferrous alloy and slag. Flueashes from power plants can also be recycled at lowcost in an environmentally-friendly manner.

The SAF is suitable for cleaning various slags whichaccumulate in the ferrous and non-ferrous industries. Typical applications in this respect are:

Slag cleaning furnaces (copper, lead, zinc)Waste oxide recycling furnaces for steel mill wastesWaste oxide recycling furnaces for flue ashes(from power plants or waste incineration plants)

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Test furnace at IME.

DC furnace for wasterecycling.

Pig iron tap.

DC-furnace roof.

Extensive knowledge in the field of ironmaking furnacesCost-favorable ironmaking processesNo need to charge lump oreWaste materials can be re-used

DECISIVE ADVANTAGES

PLANT HIGHLIGHTS

S.A. White Martins, Brazil

49.5 MVA CaC2

Namakwa Sands, South Africa

28 MVA and 30 MVA TiO2-slag

Kumba Resources, South Africa

2 x 36 MVA TiO2-slag

Rockwool Isolation S.A., France

8.5 MVA mineral wool

CBMM, Brazil

2 x 10.5 MVA and 4.2 MVA FeNb

Highveld South Africa

63 MVA pig iron

Iron Dynamics, USA

38 MVA pig iron

Xinli, PR China

30 MVA TiO2-slag

IME University Aachen, Aachen, Germany

1 MVA multi-purpose AC/DC furnace

SELECTED REFERENCES


26

ANCILLARY EQUIPMENTANCILLARY EQUIPMENT

UPSTREAM

The full range of products is available in the areas ofraw material preparation, handling, agglomerationand processing.

Raw material preparation

crushing blendinggrinding screeningmixing

Raw material agglomeration

sintering cold-briquettingpelletizing hot-briquetting

Raw material handling

transport storageweighing

Raw material processing/pretreatment

drying calcinationheating roastingreduction

DOWNSTREAM

We also provide an extensive equipment rangedownstream of the SAF, e.g. for the solidification,refining and treatment of metal, matte and slag.

Granulation (static or dynamic)Hot metal charging systems for the EAFPig-casting machinesCasting wheelsMetal/alloy handling equipmentMetal refining equipment- Ladle refining equipment- Ladle arc reheating station- LD converters / AOD converters- Deslagging stations- Chemical heating stationsHigh-voltage substationsCooling water plantsHeat recovery systemsEnergy recovery systems

Full range of equipment upstream anddownstream of the SAF for optimizedprocess requirements

Ladle furnace.

DECISIVE ADVANTAGES

Granulation system.

27

FERROALLOY REFININGFERROALLOY REFINING

The refining process for ferroalloys is highly depend-ent on the raw material and on the quality desired bythe customer. Our product portfolio includes injectionsystems, ladle furnaces, chemical heating stationsand deslagging stations These units are combined,particularly for the refining of FeNi, in order toachieve the desired product quality.

The basic form of FeNi refining is done by tempera-ture control and desulphurization. More complexapplications require a more elaborate treatment, asshown in the diagram.

To ensure maximum flexibility of the operationalsequence, the ladle cars can optionally be equippedwith inductive stirring systems.

0,47 % S

0,30 % P

0,20 % Si

0,10 % C

Tap Transp (Deslag) CH-deC/P Desl Heat/de-S Deslag de-Al Trim/transp. Granulation

Oxidising Refining Reducing Refining

TOMORROW’S SUBMERGED-ARC

FURNACE IS BEING DEVELOPED BY

US RIGHT NOW

We are constantly improving our furnace designthrough research and development programs com-bined with long-standing experience in industrialunits. Our R+D activities focus on:

DC technologycooling conceptsrefractory optimizationincreasing of process efficiencylogistical improvementprocess modelingslag managementimproved tapping systemsnumerical process simulationfinite element methodsrecycling technologies

COOPERATIONS

University of Chile in Santiago/ChileIME Process Metallurgy and Metal Recycling at the RWTH Aachen/GermanyDepartment of Ferrous Metallurgy RWTH AachenUniversityTechnical University Dortmund/GermanyUniversity Duisburg-Essen/GermanySlag-Institute Rheinhausen/Germany

University of Technology Delft/NetherlandsResearch Centre for Iron Ore Benefication andMetallurgical Testing of Burden Materials, Liebenburg/Germany

DC – INTENSIVE SLAG CLEANING

STEP (WASHING MACHINE)

We have developed a DC-based intensive slag cleaning step. This patented innovation possesses apermanent DC field combined with a magnetic fieldand cleans the liquid slag to an ultra-low level. Thesystem is compact and efficient and its investmentcosts are clearly defined. The first demonstrationplant was in operation in Chile and shows satisfactoryresults. The first economic evaluations for copper,PGM and ferroalloys promise a short amortizationperiod.


28

INNOVATIONSFOR THE FUTUREINNOVATIONSFOR THE FUTURE

Washing machine for the recycling of precious metals.

CFD simulation.

Insulation

Slag launder

Mattetap hole

Magnet poleMagnet coil

JokeShell(anti magnetic)

Lining

Coke layerGraphiliteelectrode

29

REFERENCESREFERENCES

FERRO ALLOYS

1970 – 1979 371980 – 1989 421990 – 1999 222000 – today 26Total 127

NON FERROUS

1970 – 1979 71980 – 1989 141990 – 1999 92000 – today 10Total 40

SPECIAL PROCESSES

1970 – 1979 101980 – 1989 101990 – 1999 112000 – today 7Total 38

RECYCLING/PIG IRON

1970 – 1979 131980 – 1989 11990 – 1999 12000 – today 0Total 15

MODIFICATIONS

1970 – 1979 61980 – 1989 181990 – 1999 152000 – today 17Total 56

ENGINEERING STUDIES

2 – 4 studies each year1970 – today approx. 285


30

PROCESS KNOW-HOW

Extensive process know-how, strong metallurgicalbackground knowledge based on industrial experi-ence500 reference plants installed worldwide (furnaces and furnace components)Experience with more than 50 productsMarket leader in SAF technology (50% market share for large-size furnaces)Deep know-how in AC- and DC technology

ECONOMIC ASPECTS

Economic success with solid state-of-the-art technologySteeply ascending ramp-up curvesQuick return on investment

DESIGN AND CONSTRUCTION

Highly reliabel electrode column systemMaintenance-friendly systemsAll types of electrodes availableSuitable cooling conceptsWater-cooled tap holes

Superior refractory concept in combination withbalanced cooling guarantees a long refractory lifeat minimum operating costsFailsafe hydraulic systemAdvanced electrical systemsAutomation system ensures safe, reliable andeasy operation

ENVIRONMENT

All systems for clean operation in an environmen-tally optimum manner

AFTER-SALES SERVICE

Experienced personnel for proper planning, engineering, procurement, commissioning andtraining

CUSTOMERS

The success of our customers is our best reference

SAF AND ELECTRIC SMELTERS AT A GLANCESAF AND ELECTRIC SMELTERSAT A GLANCE

Cu-slag furnace charging system.TiO2-slag production plant.

31

Tapping area of CAC2 furnace.

Copper slag.

Workshop assemblyof electrode column.

SMS SIEMAG –

WE ARE THERE FOR YOU

Over 100 years of experience in metallurgicalplantsA world leader among industrial plantmakersA strong partner for productionWide experience in the supply of turnkey plantsOur sound metallurgical background knowledgebenefits the ferrous and non-ferrous metals industryContinuous innovationExtensive experience regarding upstream anddownstream technologies

Si-metal furnace.

SMS SIEMAG AG

Steelmaking and Continuous Casting Technology DivisionSubmerged-Arc Furnaces (SAF)

Eduard-Schloemann-Strasse 440237 Düsseldorf, Germany

Phone: +49 (0) 211 881-6372 or 6180Telefax: +49 (0) 211 881-6980

E-mail: [email protected]: www.sms-siemag.com

PASSION FOR METALS

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