二,Overall introduction of the equipment

1. Working Principle

1. High-temperature electric arc (1600–2500℃) between electrode tip and raw material
2. Resistance heat generated when large current passes through solid furnace charge
   
   
   Coke/anthracite acts as reducing agent, reducing metal oxides in ore into molten alloy or calcium carbide. Continuous feeding + intermittent tapping for 24h non-stop production.

2. Core Equipment Composition

1. Furnace Main Body
   
   
   Furnace shell (water-cooled steel structure), carbon/magnesia refractory lining, furnace cover, tapping channel, slag outlet, furnace platform. Classified as open, semi-closed, fully closed furnace (fully closed for flue gas recovery & environmental protection).
2. Power Supply System
   
   
   High-voltage transformer, short net conductive system, reactive power compensation & harmonic filtering cabinet, PLC electrical control room. Supports low/high/ultra-high power models (3300kVA ~ 81000kVA).
3. Electrode Lifting & Hydraulic System
   
   
   Hydraulic cylinder, electrode holding clamps, pressure ring, electrode paste feeding device; automatic lifting adjustment to stabilize arc resistance.
4. Raw Material Batching & Feeding System
   
   
   Raw material silos, automatic weighing batcher, belt conveyor, sealed top charging chute, dust-proof feeding mechanism.
5. Auxiliary Circulation & Environmental System
   
   
   Full water cooling circulation unit, flue gas waste heat recovery, bag dust removal system, CO gas collection pipeline, desulfurization & denitrification unit.
6. Intelligent Monitoring System
   
   
   Real-time temperature, current, voltage, furnace pressure & flue gas online monitoring, automatic alarm & load adjustment.

3. Equipment Advantages

1. Multi-product Compatibility:One furnace switches between calcium carbide, ferrosilicon, silicomanganese, ferrochromium by adjusting raw material formula, flexible production line layout.
2. High Thermal Efficiency:Electrodes buried in burden reduce heat radiation loss, power consumption 8–15% lower than open arc furnaces.
3. Low Operation Cost:Self-baking electrodes save graphite consumption; fully closed furnace recycles CO flue gas for power generation or heating.
4. Stable Alloy Quality:Precise electric power control ensures stable chemical composition, high metal recovery rate ≥92%.
5. Automatic & Low Labor Intensity:Automatic batching, electrode lifting, tapping auxiliary machinery, central PLC control.
6. Green Environmental Compliance:Full sealed dust removal + waste heat recovery, meets national industrial emission standards.

4. Technical Parameter Reference Table

三,Detailed introduction of four major smelting products

1. Calcium Carbide (CaC₂)

Production Formula

Grade & Application

• Standard grade: 295L/kg, 300L/kg, 315L/kg gas yield
• Main uses:
  1. Acetylene gas generation for metal cutting/welding, PVC plastic raw material
  2. Steel desulfurizer & deoxidizer in metallurgy
  3. Raw material for pesticide, calcium cyanamide chemical synthesis

2. Ferrosilicon (FeSi45 / FeSi75 mainstream grades)

Raw Materials: High-purity quartz sand, metallurgical coke, steel scrap, lime

Core Composition (FeSi75): Si 72–80%, Fe balance, low Al/C/P impurities

Industry Applications

1. Primary deoxidizer in carbon steel, stainless steel smelting; remove oxygen from molten steel to improve mechanical performance
2. Alloy additive: enhance tensile strength, wear resistance of steel
3. Casting industry inoculant: refine graphite grain, reduce casting defects
4. Production of silicon manganese, silicon calcium composite alloys

3. Silicomanganese Alloy (FeMn68Si18 mainstream)

Raw Materials: Manganese ore, silica, coke, flux lime

Typical Composition: Mn 65–70%, Si 16–22%, C ≤2.0%

Advantages & Usage

1. Main additive for low-alloy steel, ship plate, construction steel, pipeline steel
2. Reduce oxygen & sulfur content simultaneously, improve steel toughness & weldability
3. Raw material for low-carbon ferromanganese refining

4. Ferrochromium (High Carbon / Medium Carbon / Low Carbon Ferrochrome)

Raw Materials: Chromite ore, coke, lime, silica

Main Grades & Uses

1. High-carbon ferrochrome (C 4–8%): Raw material for stainless steel, wear-resistant cast iron
2. Medium/low-carbon ferrochrome: Produce corrosion-resistant stainless steel, alloy tool steel
3. Core function: Add chromium element to form passive anti-rust film, improve hardness & oxidation resistance of steel

四,Complete Production Process Flow

五,Application Fields of the Furnace

1. Ferroalloy Metallurgy Plant: Mass production of ferrosilicon, silicomanganese, ferrochrome for steel mills
2. Calcium Carbide Chemical Plant: Acetylene chemical raw material production
3. Integrated Metallurgical-Chemical Enterprise: Multi-product flexible switching to balance market price fluctuation of alloys & calcium carbide