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<p>The AC submerged arc furnace (SAF) is the main equipment used for smelting ferroalloys, which requires a large amount of energy and carbonaceous reductants. Optimizing the smelting process to reduce the energy consumption of ferroalloy products is meaningful. In this study, a visualization model was developed to track the distribution and evolution of the furnace gas–furnace charge–slag–ferrochrome alloy, which could gain an in-depth understanding of the mass and heat transfer phenomena. The complex multiphase flow, multiphysics fields, and carbothermal reduction reactions are coupled to reproduce the smelting process in SAF. The results show that the real-time locations of furnace gas escaping and ferrochrome alloy settling are around the polar circle of the electrode. The generated alloy drips to the bottom of the furnace, where the slag is separated from the alloy. The impact of phase voltage on energy consumption was further analyzed. When the phase voltage increases from 75 to 85&#xa0;V, the average current increases by approximately 11.80&#xa0;pct, and the maximum magnetic field intensity increases by approximately 23.58&#xa0;pct. The ferrochrome alloy output only increases by about 4.67&#xa0;pct, while energy consumption rises significantly. This phenomenon stems from the flow and amount of the furnace gas, for which the maximum velocity increases by approximately 25.71&#xa0;pct. More generated furnace gas carries away heat, causing furnace heat loss. The heat and mass characteristics and variation patterns contribute to optimizing the smelting performance in ferrochrome SAF.</p>

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A Visualization Model for Tracking the Furnace Gas–Furnace Charge–Slag–Ferrochrome Alloy: Application to Electric Furnaces

  • 期刊论文

  • 发表日期：

    2026年2月3日

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  • Yang Yu,
  • Mengni Yang,
  • Zhetong Li,
  • Zhongqiu Liu,
  • Baokuan Li

摘要

The AC submerged arc furnace (SAF) is the main equipment used for smelting ferroalloys, which requires a large amount of energy and carbonaceous reductants. Optimizing the smelting process to reduce the energy consumption of ferroalloy products is meaningful. In this study, a visualization model was developed to track the distribution and evolution of the furnace gas–furnace charge–slag–ferrochrome alloy, which could gain an in-depth understanding of the mass and heat transfer phenomena. The complex multiphase flow, multiphysics fields, and carbothermal reduction reactions are coupled to reproduce the smelting process in SAF. The results show that the real-time locations of furnace gas escaping and ferrochrome alloy settling are around the polar circle of the electrode. The generated alloy drips to the bottom of the furnace, where the slag is separated from the alloy. The impact of phase voltage on energy consumption was further analyzed. When the phase voltage increases from 75 to 85 V, the average current increases by approximately 11.80 pct, and the maximum magnetic field intensity increases by approximately 23.58 pct. The ferrochrome alloy output only increases by about 4.67 pct, while energy consumption rises significantly. This phenomenon stems from the flow and amount of the furnace gas, for which the maximum velocity increases by approximately 25.71 pct. More generated furnace gas carries away heat, causing furnace heat loss. The heat and mass characteristics and variation patterns contribute to optimizing the smelting performance in ferrochrome SAF.