UNIVERSITI MALAYSIA PERLIS

LABORATORY REPORT

METAL EXTRACTION TECHNOLOGY

PDT 262

SEMESTER 2 (2016/2017)

PREPARED BY:

TITLE ELECTRIC ARC FURNACE SIMULATION

EXPERIMENT 4

GROUP A1

GROUP MEMBERS:

NAME MATRIC NUMBER

1) AIMADUDDIN BIN SALLEH 151353063

2) ALFRED LIEW YAH WOO 151353064

3)NUR NAEMAH BINTI MAT NAWI 151353110

4)NUR SYAHIRA BINTI SHAFIE 151353111

5)PIRIYADHARISANI A/P SINNA THAMBY 151353682

1) MDM NOORINA HIDAYU BINTI JAMIL

LECTURER 2) SIR MUHAMMAD QAUYUM ZAWAWI BIN
AHAMAD SUFFIN
TH 1
DATE OF SUBMISSION 18 MAY 2017
 TABLE OF CONTENT

NO ITEM PAGE

1 OBJECTIVE 3

2 INTRODUCTION 3-4

3 MATERIAL AND EQUIPMENT 5-7

4 PROCEDURE 8

5 RESULT 8

6 DISCUSSION 9

7 QUESTION 10 - 12

8 CONCLUSION 13

9 REFERENCE 14

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 CHAPTER 1

INTRODUCTION

1.0 OBJECTIVE :

a) To learn the use of electric arc furnace in steelmaking to melt recycled steel.

b) To refine the composition to produce the required new steel.

c) To know the physical processes related to the production of steel

2.0 INTRODUCTION

A well-known type of electric furnace comprises three electrodes disposed at the corners
of an equilateral triangle, which electrodes are provided with single-phase alternating current
from the secondary windings of three transformers. the three primary windings of which are
energised with current from a three-phase' mains supply.

The eiilciency'of such a known arrangement is invariably reduced more or less owing to
the fact that the alternating currents in the leads between the transformers and the electrodes
induce changing magnetic elds in each other and in the surrounding metallic parts of the
furnace, which fields increase the reactance in the said supply lead.

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 The electric arc furnace operates as a batch melting process producing batches of molten
steel known "heats". The electric arc furnace operating cycle is called the tap-to-tap cycle
and is made up of the following operations: Furnace charging, melting, refining, de-
slagging, tapping, and Furnace turn-around.

An Electric Arc Furnace (EAF) is a furnace that heats charged material by means of an
electric arc. Arc furnaces range in sizes from a small units of approximately one ton capacity
(used in foundries for producing cast iron products) up to about 400 ton units used for
secondary steelmaking.

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 CHAPTER 2

METHODOLOGY

2.0 METHODOLOGY

Equipment

1. Arc furnace
2. Transformer
3. Control box
4. Water cooling cable
5. Hydraulic pump
6. Water pump

Raw Material

1. Iron
2. Carbon
3. Oxygen
4. Electrode
5. Silicon oxide
6. Calcium oxide
7. Magnesium oxide

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Procedure Flow Chart

Load raw material in

basket

Open the roof of the

furnace

Load the basket and

transfer to furnace

Closed the roof of the

furnace

Set up the electrode

Adjust the level of

electrode

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 Adjust the bath
temperature

Load second basket

Add material to increase

the alloy content

Water cooling system

Take a sample

Start tapping

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Cost breakdown

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PROCEDURE :

1. Select iron units including recycled steel and direct reduced iron. Only selected raw
material selected shall be distributed in different basket in the order and quantity as
appropriate.
2. Open the roof of the furnace to enable buttons that allow the iron units in the baskets to
be added to the furnace.
3. The simulation can be run at a range of different speed between x1 and x32.
4. The basket is removed and the furnace roof can be closed.
5. The electrical power distributed among the three electrodes, which melt the iron units by
creating an arc between the electrode and iron units.
6. After the iron units have been melted, the temperature of the liquid metal is shown in the
panel.
7. Oxygen and carbon may be injected into the steel and slag phases respectively.
8. Water cooling panels are built into the furnace wall to help preserve the refractory lining.
9. When melting is completed, take the sample to test for the steel composition.
10. Data on the evolution of the chemical composition of the steel and slag is shown on the
graphs.
11. Once the iron unit have been melted and refined to the desired composition and
temperature.
12. The specific information about the main costs of production and other consumables is
shown as well as total cost of production and cost per lonne.

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 CHAPTER 3 :

RESULT AND DISCUSSION

3.1 RESULT

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 3.2 DISCUSSION

In Electric Arc Furnaces simulation that we run, there is an error on tap temperature, total
time and final slag composition. To tap temperature, occur because of errors in the simulation,
we can not control the temperature with the right proportions during mass transfer into a single
bucket. In addition, each bucket load will also affect their slag compositon when moved into
furmace. Total time taken by us while doing this simulation is quite long, which will greatly
affect their error when the simulation is run.

The effects of voltage flicker caused by the EAF loads are investigated. Attention was
focused on the generator units installed in cogeneration plant that supplies the 154-kV bus
nearby Aliaa region. Computer simulations show that the generators do not have any stability
problem in the presence of continuous flicker disturbance and such a problem has not been
reported so far. However, the instantaneous electromagnetic torque oscillations are quite high,
which imposes stress and fatigue on mechanical shaft system components and the situation may
yield to a complete failure over a long-term period.

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 CHAPTER 4 :

CONCLUSION

4.1 CONCLUSION ::

In conclusion, the main objective of the experiment was achieved that is to learn the use

of electric arc furnace in steelmaking to melt recycled steel. The electric arc furnace operates as a

batch melting process producing batches of molten steel known "heats". The electric arc furnace

operating cycle is called the tap-to-tap cycle and is made up of the following operation like

Furnace charging, Melting, Refining, De-slagging, Tapping, Furnace turn-around. These refining

reactions are all dependent on the availability of oxygen. Oxygen was lanced at the end of

meltdown to lower the bath carbon content to the desired level for tapping. Most of the

compounds which are to be removed during refining have a higher affinity for oxygen that the

carbon. At the end of refining, a bath temperature measurement and a bath sample are taken. If

the temperature is too low, power may be applied to the bath.

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 CHAPTER 5

REFERENCE

5.1 REFERENCES :

1) Raoul, N. (1945). U.S. Patent No. 2,368,998. Washington, DC: U.S. Patent and
Trademark Office.

2) https://www.slideshare.net/e_gulfam/electric-arc-furnace

3) [2] C. Sankaran, ‘Power Quality’, CRC Press, 2002.

4) IEEE Std 1453-2004, ‘IEEE Recommended Practice for Measurement and Limits of
Voltage Fluctuations and Associated Light Flicker on AC Power Systems’, 2005.

5) IEEE Std 141-1993, ‘IEEE Recommended Practice for Electric Power Distribution for
Industrial Plants’, 1994.

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