A submerged arc furnace is an industrial electric furnace characterized by high power consumption. It primarily consists of a furnace shell, furnace cover, lining, short-network system, water-cooling system, exhaust and dust removal systems, electrode casings, electrode clamping/slipping and lifting mechanisms, material charging and discharging systems, electrode holders, taphole openers, a hydraulic system, a furnace transformer, and various electrical components.
Based on the structural and operational characteristics of the furnace, approximately 70% of the system's reactance originates from the short-network system. As this system operates at very high currents-reaching tens of thousands of amperes-its performance directly determines the overall performance of the furnace. Consequently, the natural power factor of such furnaces rarely exceeds 0.85, with the vast majority falling between 0.7 and 0.8. A low power factor not only reduces transformer efficiency and results in significant reactive power loss but also incurs financial penalties from utility companies. Furthermore, manual electrode control and material piling practices exacerbate electrical imbalances among the three phases-sometimes exceeding 20%-leading to reduced smelting efficiency and increased electricity costs. Therefore, improving the short-network power factor and mitigating grid imbalance are effective strategies for reducing energy consumption and enhancing smelting efficiency. Implementing appropriate measures to improve the short-network power factor can yield the following results:
(1) Reduce electricity consumption by 5%–20%;
(2) Increase output by 5%–10% or more .