Bansal Ferro Alloy Consultants
Engineering Excellence in Ferroalloy Production
Engineering Excellence in Ferroalloy Production
Revolutionary technologies and solutions for energy efficiency in ferroalloy production
Huge Eddy Current Losses that occur essentially during operation of Submerged Arc Furnaces with Traditional Design are completely Eliminated which results in Saved Power to be used in the Furnace and hence enhances productivity.
By making Certain Innovative Modifications in the structures (AS SHOWN IN THE MARKED AREAS BELOW) during erection. Next Part comes at the time of Floor Casting of the Furnace Floor.
IĀ²R Losses are Minimized by using Properly Designed Secondary Circuit. Bus-Tubes constitute the major portion of the secondary Circuit in a SAF. Instead of Conventional Circular Bus Tubes it is strongly advised to use Square Bus Tubes as shown here.
1. Optimum Cross Section Area of Copper
2. Optimum Vertical Spacing as well as Horizontal Spacing
3. Optimum Water Flow and Pressure consideration
4. ššØš«šš§šš³ š šØš«šš šššš°ššš§ šš®š¬ šš®ššš¬: When current flows through parallel bus tubes, a magnetic field is generated around each conductor. The interaction between this magnetic field and the current flowing in adjacent conductors results in a force, known as the ššØš«šš§šš³ ššØš«šš. This force is repulsive as the currents flow in opposite directions.
5. The Lorentz force can cause mechanical stress, deformation to the bus tube system if not designed properly (Optimum Spacing) and proper pre calculations of the Lorentz Forces
Square tubes have a larger surface area. This increased surface area allows for more efficient ššš š§ššš¢š š š¢šš„š ššš®šš«šš„š¢š³ššš¢šØš§ and hence considerably šš¢š§š¢š¦š¢š³š¢š§š šš”š šš¦š©šššš§šššš šØš š¬šššØš§ššš«š² šš¢š«šš®š¢š ššÆšš§šš®šš„š„š² š„šššš¢š§š ššØ š¦š¢š§š¢š¦š¢š³š šĀ²š ššØš¬š¬šš¬. šš¦š©š«šØšÆšš ššØš°šš« š ššššØš« šš§š”šš§ššš¬ šš«šØšš®ššš¢šÆš¢šš².
Furthermore, Magnetic Flux Linkage with surrounding structures is reduced considerably resulting in improved Power Factor and hence the productivity.
It is important to note here that for a 9-12 MVA Furnace, the quantity of Copper is saved up to 1.3 to 1.5 MT as compared to the conventional design.
For further minimizing the šĀ²š Losses, it is strongly recommended to use Copper with Conductivity 103-105% IACS. (IACS stands for: INTERNATIONAL ANNEALED COPPER STANDARD). Zambian Copper with Silver Traces has conductivity of that order. This reduces losses further to 3-4%.
In order to make optimum use of the Transformer Capacity, the specially Secondary Compensation Capacitor Bank is installed (Tailor Made for Every Furnace). The beauty of this arrangement is that the Furnace Power Factor is maintained close to unity at all loads. As we increase the secondary voltage from Tap1 to the highest Tap, the KVAR output of the Capacitor Bank increases proportionately. Since the Furnace Power Factor is optimum, the efficiency and hence the production also increases.
For Example: If Power Factor of the Furnace is increased from 0.8 to 0.98, 10 MT production will increase per day for SiMn for a 9 MVA Furnace.
There are certain ways to use wasted heat for Pre-Heating ores before charging in the Furnace. However, it requires some Specially Designed Infrastructure, a one time investment.
From above explanation it can be easily assessed, how much the Cumulative Effect is.
In Addition to the above There are several other ways to Save Power.