Direct Current Electric Arc Research Articles

Melt azimuthal rotation in direct current electric arc furnace without external axial magnetic field

This paper considers the azimuthal rotation of melt about the vertical axis of a DC EAF, which is ensured by an inclined installation of the power supply electrodes, which is a patented solution that is the basis for this article. Near inclined electrodes, the Lorentz force has a pronounced azimuthal component, which is the driver of the melt rotation without an external axial magnetic field – thus, additional energy consumption to create an external magnetic field is not necessary. The main design and technological solutions, formulated in the patent and presented by the authors, were obtained using observations and numerical LES study for a laboratory-scale experimental setup (capacity 4.8 kg of GaInSn), as well as using LES computations for an industrial-scale DC EAF (capacity 3.6 t of molten steel). Basic technological solutions studied: the flow of the melt may be controlled by varying the number of vertical and inclined electrodes of DC EAF, choosing the angle of inclination of the electrodes as well as choosing the sequence of turning on and turning off power supply through the electrodes.

Numerical modelling of heating and melting of metal in a mini industrial direct current electrical arc furnace

Purpose The purpose of this paper is the study of the electro-vortex flow (EVF) as well as heating and melting processes for mini industrial direct current electric arc furnace (DC EAF). Design/methodology/approach A mini DC EAF was designed, manufactured and installed to study the industrial processes of heating and melting a small amount of melt, being 4.6 kg of steel in the case under study. Numerical modelling of metal melting was performed using the enthalpy and porosity approach at equal values and non-equal values of the solidus and liquidus temperatures of the metal. The EVF of the liquid phase of metal was computed using the large eddy simulation model of turbulence. Melt temperature measurements were made using an infrared camera and a probe with a thermocouple sensor. The melt speed was estimated by observing the movement of particles at the top surface of melt. Findings The thermal flux for metal heating and melting, which is supplied through an arc spot at the top surface of metal, is estimated using the thermal balance of the furnace at melting point. The melting time was estimated using numerical modelling of heating and melting of metal. The process started at room temperature and finished once whole volume of metal was molten. The evolution of the solid/melt phase boundary as well as evolution of EVF patterns of the melt was studied. Originality/value Numerical studies of heating and melting processes in metal were performed in the case of intensive liquid phase turbulent circulation due to the Lorentz force in the melt, which results from the interaction of electrical current with a self-magnetic field.

Effect of compressibility on industrial DC electric arcs

The paper reports on the behaviour and dynamics of direct current electric arc in an industrial electric arc furnace. Electric arcs are intense energy sources involved in many industrial processes. The behaviour of electric arc is simulated in a 2D axisymmetric geometry. A 40 kA current flows between two electrodes with a gap of 0.25 cm. The flow of current creates a very powerful jet up to km/s. Such speeds pose the question of the importance of compressibility and what is the extent of the effects of compressibility on arc behaviour. To assess the effect of compressibility, two different simulations are performed: an incompressible and a compressible simulation. The first simulation considers a temperature-dependent density based on experimental measurement whereas the latter adopts the ideal gas law to calculate the density variation of the plasma. The incompressible results were previously validated and compared to the well-known results predicted by the literature. The numerical results of the two models are reported and compared in terms of flow, thermal fields, and voltage drop. The results show that compressibility affects several aspects of the arc. As expected, the velocity drops when compressibility is present, however, the voltage drop increase significantly. Additionally, compressibility introduces a repetitive pattern of voltage drop over time which also depicted in the arc dynamics. The pattern is divided into three distinctive dynamics: (1) High-frequency low amplitude instabilities, followed by (2) low low-frequency high amplitude instabilities region, and finally, a relatively (3) stable interval of voltage with a bell-shaped arc.

Optimisation of the operating parameters of a thermal plasma system for the conversion of waste containing polychlorinated biphenyls by thermodynamic modelling

This paper proposes a mathematical modelling approach to determine the thermodynamic equilibrium of chemical systems in order to optimise the operating parameters of the plasma chemical processes in a low-temperature thermal plasma pilot reactor with a direct current electric arc for the treatment of hazardous waste containing polychlorinated biphenyls. The model is primarily based on the principles of mass action and minimum Gibbs free energy. The obtained results can serve as a basis for multi-criteria optimisation based on ecological aspects, reduction of energy consumption and the possibility of using the produced synthetic gas for energy recovery in the process. The analysis carried out clearly showed the advantages of using water vapour as a plasma working medium and the appropriate mixing of the organic waste containing polychlorinated biphenyls with used engine oil for enriched syngas production. The presented analysis determines the optimal reactor temperature for an ecologically efficient treatment and shows possibilities for energy recovery in the process. The proposed model can also be used for other chemical reactors and for the treatment of other chemical substances.

Investigation of Upgraded Technology for Plasma Spraying of Bronze Powder Using the Combined Process with Hydrocarbon Additions

The object of the research is thermal spray process for the formation of metal coating from bronze powder in plasma-fuel variant, using direct current (DC) electric arc plasma torch, on steel samples. The aim of the work was to investigate and develop the technology for plasma-fuel spraying of functional coatings (for wear-resistant and antimicrobial applications) on machine-building and medical purpose pieces with increased process capacity and moderate energy consumptions in a comparison with conventional thermal spray technologies with use of inert and oxygen-free gas media. During the study, using experimental and thermodynamic estimation methods, the thermal and chemical parameters of the process under the spraying conditions at ambient pressure were characterized, which made it possible to determine the area of preferred regimes of the developed technology. On the modernized testing unit for plasma spraying of metal powders with power of up to 40 kW, operating using a controlled combination of three types of gases – technical nitrogen and propane-butane (LPG) with compressed air, the measurement and optimization of the operating and constructive/assembling parameters of the system for aluminum bronze coating spraying were established. In this case, the experiments were carried out using the designed fuel intensifier, which is joined with the PP-25 arc plasma torch, as well as additional technological equipment (protective shroud). For samples of the resulting coatings with a thickness of 100 to 450 mm from the bronze material, testing of phase composition and some parameters of the resulting coatings on steel products was carried out. Operating capacity of the proposed process reaches 7–15 kg/h for bronze powder when using a moderate power of the torch – up to 35–40 kW and a limited flow rate of hydrocarbon gas (for example, LPG of the SPBT grade) – 0.1–0.35 kg/h. Analysis of the energy efficiency parameters of the developed technology, as well as its calculated technical characteristics, in a comparison with plasma and combined equipment of a similar purpose, showed that it has an advantage in terms of target indicators, in particular, in terms of energy consumption and total energy efficiency of the spraying unit, not less than 20–30 %. This makes it to proceed later to the stage of application of this technology into production based on a new process for the metal coating formation, in particular with antimicrobial properties, with improved energy efficiency of the process.

Study on Mechanism of Titanium Slag Smelting in DC electric Arc Furnace

Based on the production practice of a 30MWA large DC electric furnace in Yunnan, this paper discusses the basic reactions in smelting titanium slag, and discusses the thermodynamic and kinetic behaviors of the main elements and impurities. The results show that the reduction reaction in the smelting process is carried out simultaneously in the multi-component system of Al2O3-CaO-MgO-SiO2-TiO2. The titanium slag containing more than 80% TiO2 can be obtained by enrichment smelting of ilmenite in a large high-power enclosed direct current electric arc furnace, and the output includes by-product pig iron. Impurities MgO, CaO and Al2O3 in titanium concentrate will not be reduced during reduction smelting; SiO2, MnO and V2O5 will be reduced in varying degrees, and the reduced products Si, Mn and V will dissolve in the metal Fe phase or be enriched in titanium slag.

Characteristics Analysis of Fluid Flow and Heating Rate of a Molten Bath Utilizing a Unified Model in a DC EAF

Herein, a 2D unified model coupling a plasma arc–molten bath–cavity in a direct current electric arc furnace was developed for a characteristic analysis of the fluid flow and heating rate of the molten bath. The ‘local thermodynamic equilibrium–diffusion approximation’ method was employed for the physical phenomenon at the plasma arc/molten bath interface, and the volume-of-fluid method was used to track the free surface. After ensuring model validation, the formation processes of the cavity and the flow field and heating rate of the molten bath were investigated by utilizing the unified model. The numerical results showed that the formation processes of the cavity contained three stages, namely the expansion, compression, and dynamic equilibrium stages. The arc pressure and plasma shear stress both contributed to the cavity formation, and dominated the expansion of the cavity depth and diameter, respectively. Under plasma arc jet impingement, there were two flow patterns inside the molten bath: (i) a clockwise eddy on the top surface and lateral part of molten bath dominated by plasma shear stress, and (ii) a counter-clockwise eddy in the bottom part of the molten bath dominated by the electromagnetic force. Meanwhile, the main heated region of the molten bath with the plasma arc–molten bath–cavity coupling was in the radial range of 0.2–0.6 m, and a high-temperature region was formed on the top surface of the molten bath caused by plasma shear stress.

Comparison of DC Electric Arc Furnace Chaotic Models for Power Quality Indices Assessment

Due to their particular feature, direct current (dc) electric arc furnace (EAF) installations are peculiar loads that cause moderate to severe power quality (PQ) disturbances in the feeding power systems. Among them, voltage fluctuations and waveform distortions are the most impactful ones, and they should be adequately addressed in order to mitigate the detrimental effects. Several types of models have been developed in order to evaluate the effects of EAFs on networks, and chaotic models have been specifically recognized as suitable tools to evaluate the impact of EAFs in terms of PQ disturbances. This article compares the performance of three chaotic models (Chua, Lorenz, and Rössler) aiming at estimating PQ indices values of dc EAFs. The procedure exploits a block diagramming tool of the dc EAF installation and minimizes the deviation of estimated PQ indices from the actual ones through a new Monte Carlo optimization procedure, performed upon the parameters of the three chaotic models. To comply with the time-varying nature of the current and voltage waveforms in a dc EAF installation and with the wide presence of interharmonics, traditional, and advanced PQ indices are considered in this article. Actual data collected at an Italian dc EAF installation are used to conduct a numerical comparative analysis and to validate the effectiveness of the models in estimating the PQ disturbances.

Model of a non-transferred arc cascaded-anode plasma torch: the two-temperature formulation

This study presents an analysis of a three-dimensional unsteady two-temperature simulation of atmospheric pressure direct current electric arc inside a commercial cascaded-anode plasma spray torch; it coupled the arc model with the torch electrodes and used an open-source computational fluid dynamics software (code_saturne). The previously published models of plasma spray torch either deal with conventional plasma torches or assume local thermodynamic equilibrium in cascaded-anode plasma torches. The paper presents the computation of the two-temperature argon plasma properties, compares two enthalpy formulations that differ in association of the ionization part of enthalpy and finally demonstrates the influence of the radiation heat loss data by comparingthe results for two different literature sources. It is the first to compare different enthalpy formulations in the context of plasma torch and discuss the differences in terms of the enthalpy gains and losses. It also explains why an unphysical simulation artifact of electron temperature lower than the heavy species temperature can occur in simulated plasma flow. The solution, then, consists in associating the ionization part of enthalpy to electrons and selecting the appropriate source of the data of radiation heat loss. However, negligible thermal non-equilibrium persists even in the hot core of electric arc, which ensures that the heavy species are heated up by collisions with electrons. The flexibility of the open-source software allows all the necessary modifications and adjustments to achieve satisfactory simulation results. Thus, the paper could be considered as a manual for development of a plasma spray torch model.

Toward a Simplified Arc Impingement Model in a Direct-Current Electric Arc Furnace

A 2D axisymmetric two-phase model was developed to study the effect of an arc impingement on the liquid metal inside an electric arc furnace. In addition to the arc flow dynamics, the model covered the heat transfer and magneto hydrodynamics of the arc and the liquid metal. Through a parametric study, three different parameters were considered to predict the most important factors affecting the arc and overall behaviour of the process: the arc gap, the density of the gas, and the total electric current. Understanding the effect of these parameters can show the key factors altering the arc dynamics. The study showed that the total applied current was the most important parameter that influenced the impingement depth and mixing of the liquid metal. The depth of the impingement and strength of the mixing of the liquid bath were directly proportional to the current applied in the furnace. The initial arc gap distance was found to be crucial for sustaining a continuous and stable arc. The value of the gas density was very important for the velocity profile; however, it had no significant effect on the impingement depth. This showed that a constant density could be used instead of a varying gas density with temperature to increase the computational efficiency. The study assessed the effects of the aforementioned factors on the arc impingement depth, velocity magnitude, and arc stability. The conclusions acquired and challenges are also presented.

High‐performance nanostructure Fe 2 O 3 synthesized via novel direct current electric arc method as sulfur‐wrapping matrix for lithium‐sulfur batteries

High‐performance nanostructure <scp> Fe ₂ O ₃ </scp> synthesized via novel direct current electric arc method as sulfur‐wrapping matrix for lithium‐sulfur batteries

Design and Construction of a Laboratory-Scale Direct-Current Electric Arc Furnace for Metallurgical and High-Titanium Slag Smelting Studies

A novel direct-current electric arc furnace (DC-EAF) was designed and constructed in this study for experimentally investigating high-titanium slag smelting, with an emphasis on addressing the issues of incomplete separation of metal and slag as well as poor insulation effects. The mechanical components (crucible, electrode, furnace lining, etc.) were designed and developed, and an embedded crucible design was adopted to promote metal-slag separation. The lining and bottom thicknesses of the furnace were determined via calculation using the heat balance equations, which improved the thermal insulation. To monitor the DC-EAF electrical parameters, suitable software was developed. For evaluating the performance of the furnace, a series of tests were run to determine the optimal coke addition under the conditions of constant temperature (1607 °C) and melting time (90 min). The results demonstrated that for 12 kg of titanium-containing metallized pellets, 4% coke was the most effective for enrichment of TiO2 in the high-titanium slag, with the TiO2 content reaching 93.34%. Moreover, the DC-EAF met the design requirements pertaining to lining thickness and facilitated metal-slag separation, showing satisfactory performance during experiments.

Numerical Analysis of Fluid Flow and Heat Transfer by Means of a Unified Model in a Direct Current Electric Arc Furnace

Herein, a unified 2D axially symmetric model coupling the plasma arc and molten bath in a direct current electric arc furnace is established, with the physical phenomena at the plasma arc/molten bath interface to be confronted by the “local thermodynamic equilibrium diffusion approximation” method. After ensuring model validation and grid independence test, the fluid flow and heat transfer processes are analyzed. The numerical investigation reveals that in terms of the relative importance of driving forces in the molten bath, an anticlockwise eddy is formed at the molten bath center driven by electromagnetic force, whereas a clockwise eddy is formed near the lateral part of the molten bath driven by buoyancy force. Regarding the distribution of heat flux, the convection–conduction and radiation heat govern the rate of heat transfer from the plasma arc to the molten bath. In addition, for larger arc current, higher arc power in the plasma arc region and higher heating rates in the molten bath are obtained when the arc length is held constant; for shorter arc length, lower arc power in the plasma arc region but higher heat transfer efficiency in the molten bath is attained when the arc current is held constant.

The destruction of pure metal cathodes during the initiation of direct current arc

In this work, the behavior of cathodes made from pure tungsten and pure hafnium in the direct current electric arc at 200 A and in atmospheric pressured argon medium was investigated. The research was focused on the processes happening with the cathodes during the arc initiation phase (first 100 ms after the power input). The processes of rapid cathode destruction were registered, and can be characterized as the destruction of the cathode in liquid phase due to electro-magnetic forces. Characteristic times of the whole process were recorded, as well as the changes in temperature fields on the cathodes surfaces and the rate of mass loss for both types of cathodes. It has been shown that the initial destruction of the cathode plays a major role in the cathodes resource life.

Research of features of structure formation in case of surface steel hardening

The geometric characteristics, microhardness and features of structure formation were studied in the heat-affected zone during the surface hardening of 09Г2, 20ФЛ, 45XHM, 65Г steels with direct current electric arc in argon. It is shown that the depth of zone with thermally modified structure is 0.7–1.2 mm with a tendency to decrease at maximum values of arc speed. Reheating of previously formed local hardening zone is accompanied by certain decrease in surface hardness, however, by changing the overlapping, the hardness of treated surface can be optimized with achieving of formation of regular structure. A regular gradient structure with periodically changing phase composition and microhardness is formed in the surface layer of steel that has been thermally treated with an electric arc. By changing the parameters of the processing conditions (electric arc current, speed of its movement, overlap of local hardening zones), it is possible to purposefully form a certain structural-phase state of the steel surface with properties that meet the operating conditions.

Multi-Physics Modeling of Steel Ingot Melting by Electric Arc Plasma and its Application to Electric Arc Furnace

Arc melting is one of the commonly-used melting methods in modern material manufacturing. The present study established a numerical model coupling the electric arc plasma, solid melting, and liquid flow together to simulate the steel ingot melting process using the electric arc. The direct current (DC) electric arc behavioral characteristics with varying arc length generated by the moving electrode were analyzed based on the validated model. The effects of both the initial arc length and the dynamic electrode movement on the steel ingot melting efficiency were studied. A potential method was also proposed to apply the established model in simulating the electric arc furnace (EAF) scrap melting. The study reveals that a reasonable and stable arc length can provide higher instantaneous heat flux and current density and reduce the arc dissipation, meanwhile balance the electrode consumption rate and melting efficiency to achieve the highest economic benefit. In addition, the dynamic electrode movement during the melting process maintains the original arc performance near the ingot top surface, which also results in a positive impact on the melting efficiency.

Shunting the electric arc helical spiral turns (numerical simulation)

A numerical simulation was performed for an open direct current (dc) electric arc in a uniform external axial magnetic field. The calculation was carried out in the frameworks of a non-stationary three-dimensional mathematical model in approximation of partial local thermodynamic equilibrium of plasma. The model does not presuppose a helical shape of the arc, as is customary in theoretical studies based on linear perturbation theory. It was shown that the helical shape of an open arc is not constant in time and periodically collapses with subsequent restoration. In a certain range of external parameters of the arc (current strength, inter-electrode distance, and external axial magnetic field), a new mode of destruction of a regular structure was revealed – the arc section shunting between the spiral turns. Shunting can be single or double when the breakdown occurs simultaneously in two places. Apparently, it is caused by convective heat transfer by plasma flows as well as by the sliding of the arc thermal field. The appeared thermal field creates a zone of electric conductivity in which the breakdown occurs.

Enhanced magnetorheological effect and sedimentation stability of bimodal magnetorheological fluids doped with iron nanoparticles

The improvement of properties of magnetorheological fluids and mechanism study has long been a classic area within the field of magnetorheological materials. This article was undertaken to dope the iron nanoparticles synthesized by direct current electric arc discharge with the traditional carbonyl iron powders to prepare bimodal magnetorheological fluids with different doping ratios. Their rheological properties and sedimentation stability were evaluated to explore the influence rules and mechanisms. The results indicate that the effect of the addition of iron nanoparticles on rheological properties under magnetic field is a combination of two opposing factors such as the strengthening of the structure and the weakening of magnetization. The sedimentation stability of the bimodal magnetorheological fluids improved significantly with the increase in the proportion of iron nanoparticles, which is attributed to the help of both free state and adsorbed state iron nanoparticles in magnetorheological fluids. Furthermore, within a specific magnetic field strength range, the bimodal magnetorheological fluids with a small proportion of iron nanoparticles can achieve an improvement in both rheological property and sedimentation stability compared with carbonyl iron particles–based magnetorheological fluids.

Analysis of Economic and Energy Efficiency of Using Electric-Arc Reduction for Iron-Containing Materials

For many years an important task for metallurgical scientists is the search for alternative technologies of iron production from mineral raw materials without using expensive coke, natural gas and with the least pressure on ecology. Technologies are required with maximum extraction of iron from ore, and with the least pollution of the atmosphere using cheap and least scarce reducing agents, for example power generating coal. Recently in OAO VNIIMT a new method has been developed and proven under laboratory conditions for direct preparation of iron by reduction of fine-grained material with solid reducing agent in a direct current electric arc furnace, including ground ore, iron-bearing sludge, etc. This technology makes it possible to prepare cast iron containing 3–4% carbon in a molten condition that may be granulated, cast into pigs, and treated in a ladle-furnace unit with minimum specific yield of gas and slag.

Analysis of electric arc furnaces efficiency via frequency spectrum-based arc coverage detection

We introduce the analysis of variables measured outside a direct current electric arc furnace that are related to the arc coverage and its electric energy efficiency. We derive an on-line reference to the arc coverage suitable for control decisions. In order to do so, we study the furnace shell vibration frequency spectrum as structure-borne sound sensed by a microphone. The data is analysed using real time software tools to obtain the sound signal spectrum associated with arc coverage likewise related to the optimal performance of the furnace. A statistical test is performed to prove the relationship between sound and electric energy efficiency.