45000 KVA Silicon-manganese Submerged Arc Furnace

All incoming raw materials are transported by truck or train to the raw material storage yard. After processing, they are conveyed to the batching station by grab cranes, belt conveyors, or loaders. Qualified raw materials are then weighed and mixed in specified proportions by the batching system. The blended materials are sent to the electric furnace for smelting. The mixed charge is continuously fed into the furnace through a surge bin, furnace-top belt conveyor, circular distribution car, storage bin, and feed pipes. Inside the furnace, the charge undergoes continuous electrothermal reduction, and the resulting molten alloy accumulates at the furnace bottom. Tapping operations are carried out at regular intervals.

During tapping, the tap hole is opened using a drilling machine, allowing the molten alloy to flow into the ladle on the ladle car, while the silicon-manganese slag overflows into slag pots or launders. After tapping is completed, the tap hole is sealed using a mud gun. The ladle car (and silicon-manganese slag pot car) is transported to the casting area. After slag skimming, alloy casting is carried out using an overhead crane or a tilting machine. Casting of silicon-manganese alloy can be performed using a casting machine or a layered casting pit. After cooling, the alloy is sampled and tested, then transported to the finished products bay for crushing, screening, and packaging. After casting, the ladle is cleaned, repaired, and baked, preparing it for the next tapping cycle.

The gas generated during the smelting process of a fully enclosed submerged arc furnace is a clean energy source with a high calorific value. It can be directly used for raw material processing equipment such as roasting and drying within the plant, and can also serve as a heat source for a gas power generation system. The electricity generated by the gas power system can be directly used to offset production power consumption.

The dust concentration in the purified exhaust gas is less than or equal to 10 mg/Nm³, meeting the local environmental regulations and atmospheric pollutant emission standards.

The control system adopts a computerized network-based control system. A control scheme combining PLC control, computer systems, electrical drives, and automatic instrumentation is implemented. The PLC system uses the Siemens S7-1500 series, which can monitor in real time the operating status and data of key process equipment in the raw material system, batching system, furnace system, and dry gas cleaning system (or all plant equipment).