Mass and energy analysis of electric arc furnace based on chemical compound in the iron and steel industry

Improvement studies to be carried out in the EAFs, which are the first place in industrial energy consumption, are of great importance in terms of energy saving and minimization of waste materials that can not be recycled. The demand for energy and the management of the waste products, which are increasing in direct relation with the escalating supply and demand equilibrium in the iron and steel sector, has a great importance for both our country and other countries in terms of country politics. The big part of the studies on reducing energy consumption in steel and iron industries are concentrated on the flue gases or slag waste heat recovery systems. Although these studies are correct and necessary, the studies done for recovering waste energy should be primarily on the waste material management. The flue gases and slag which come to mind first when it comes to waste products of the furnaces contain a large part of the lost energy. Therefore, the fuel, ore and alloying elements should be used at optimum levels to reduce the energy needing of the systems. In addition to all these, it is also important to study the basicity of the system so that the furnace operates regularly and the system is not damaged. Very low basicity adversely affects the metallurgical and chemical mechanisms of refractory erosion and also the produced slag becomes in very liquid phase. On the other hand, at very high basicity, the thermal and metallurgical efficiency of the furnace decrease due to low viscosity in the slag. For this reason, it is desirable that the basicity ratio is in the range of 1.8 to 2.3 so that the slag becomes creamy in this phase. At low basicity, sulphur removal from the system cannot be done and it can damage the refractories of the furnace. At high basicity, excess solid slag forms, which makes it difficult for the electric arc to enter the liquid steel and does not saturate in the metallurgical sense. It is emphasized that it is possible to go to the savings by controlling the consumption of the materials used in the system according to the basicity ratio. In this study, each reaction in the electric arc furnace was investigated and mass and energy balances were made. The studies that can be done to increase the efficiency of the furnace are emphasized. In this study, it was emphasized that the ratio of silicon in the scrap and the slag basicity ratio are very important parameters for the optimization of electric arc furnaces. The furnace was examined at different basicity ratios ranging from 1.8 to 2.3 and at the fixed silicon rate (1.42%) in the scrap. The existing basicity ratio of the system was calculated to be 1.87, and when the ratio was changed from 1.8 to 2.3 basicity ratio, the amount of lime consumed increased to 8 tonnes from an average of 6 tonnes, the output of slag increased from 14 tonnes to 18 tonnes and the consumed electricity energy decreased averaged 128 GJ to 124 GJ. When the basicity ratio is kept constant (1.87) and the silicon ratio in the scrap is changed from %1.42 to % %0.5, the amount of lime consumed is reduced from 6 tons to 2 tons and the slag mass is reduced from 15 tons to 6 tons and the electricity energy is increased from 128 GJ ' up to 160 GJ. It is desirable that this information does not approach the value of the optimum basicity of the slag to 2.3 in the light