The main stream of continuous charging Electric Arc Furnace(EAF) from CHNZBTECH takes as CONSTEL process. In the electric arc furnace steelmaking with the Consteel process, the adopted plant solution is the continuous feeding of this continuous casting furnace by the scrap, pre-heated and conveyed through a conveyor moving in a pre-heating tunnel, in which the exhaust gas from EAF, flowing counter-current of metallic charge is combusted by injected air. The continuous feeding and preheating of scrap offer some potential advantages compared to the conventional EAF batch feeding.
The Consteel process boosts productivity and improves energy efficiency of the continuous casting furnace with minimum environmental impact. The main highlights in implementing this continuous casting furnace technology are the conservation measures such as recovery of heat from furnace exhaust gas to pre-heat scrap prior to charging in the furnace, reduction in specific electrical energy, reductions in O2 (oxygen), and C (carbon) usage with no burner fuel consumption, increased production rate due to decreased tap-to-tap time, significant decrease in electrical disturbances on the network, lower electrode consumption and electrode breakage, increase in scrap yield, less dust is evacuated to the bag house, and cost reduction.
More environmentally friendly, fume generated by steel making from the continuous casting furnace mouth in the opposite direction with scrap charging ensures up to 300-350 ℃ preheating temperature to lower consumption.
This amount of preheating typically reduces energy consumption by 40 kWh/ton to 60 kWh/ton, electrode consumption by around 0.35 kg/ton, refractory consumption by around 1.2 kg/ton and tap-to-tap time by around 5 minutes to 6 minutes.
Key advantage over conventional batch processes where scrap is melted by the direct action of the electric arc. The EAF continuous casting furnace gases are sent to the exhaust gas cleaning plant in conditions suitable for the complete combustion of carbon monoxide (CO) and other pollutants without any fuel consumption.
CONSTEEL EAF proven benefits includes fast payback, high flexibility, environmental friendliness, safety of the operational personnel, minimum disturbance to the electric network, reduction in logistics, maintenance and manpower costs, improved use of chemical energy, lower electrode consumption, increase in scrap yield compared to batch-charged furnaces, continuous casting furnace control and optimization of operational parameters, and improved charge control through automated scrap quantity and quality tracking.
Parameter Category | Parameter Item | Unit | Typical Value (Small-Medium: 10-60t) | Notes/Remarks |
Basic Capacity & Charging System | Nominal Tapping Capacity | t | 10-60 | Rated steel output per heat, continuous feeding matching |
Continuous Charging Capacity | t/h | 5-30 | Stable feeding rate, adjustable according to melting progress | |
Scrap Preheating Temperature (Optional) | ℃ | 200-500 | Reduce power consumption, improve melting efficiency | |
Electrical System | Transformer Rated Capacity | kVA | 5000-60000 | Matched with continuous melting load, stable power output |
DC Input Power (Typical) | MW | 8-65 | Effective power at DC side, adapting to continuous operation | |
Electrode Diameter | mm | 350-650 | High-power graphite electrode, low consumption for continuous work | |
Input Voltage Level | kV | 10-35 | Compliant with industrial power grid standards, stable power supply | |
Furnace Structure & Lining | Furnace Shell Inner Diameter | m | 3.8-6.5 | Reasonable molten pool space, adapting to continuous feeding |
Furnace Shell Height | mm | 1000-1800 | Matching charging port and furnace cover structure | |
Refractory Lining Material | - | MgO-C brick / Al₂O₃-SiC-C brick | Resistant to high temperature, erosion and thermal shock | |
Furnace Cover & Charging Port | - | Water-cooled integral cover + sealed port | Reduce heat loss and dust emission, ensure sealing | |
Continuous Melting Performance | Tap-to-Tap Time | min | 35-80 | Shorter than batch furnace, continuous feeding shortens cycle |
Specific Power Consumption | kWh/t | 300-360 | Lower due to continuous molten pool and optional preheating | |
Oxygen Consumption | Nm³/t | 20-35 | For combustion support, decarburization and melting acceleration | |
Electrode Consumption | kg/t | 0.8-1.6 | Lower than batch furnace, stable arc reduces consumption | |
Metal Yield | % | 88-92 | Higher due to less scrap loss and stable melting process | |
Continuous Operation Duration | h | 24-72 | Continuous operation without frequent shutdown for charging | |
Operation & Environmental Protection | Tapping Tilt Angle | ° | 18-22 | Standard tapping angle, ensuring complete steel output |
Slagging Tilt Angle | ° | 12-16 | Facilitate continuous slag removal during operation | |
Dust Removal Efficiency | % | ≥99.2 | Sealed structure + high-efficiency dust removal, meet emission standards | |
Noise Level (1m away) | dB(A) | ≤83 | Noise reduction treatment, compliant with workplace health standards | |
Auxiliary System | Cooling System Type | - | Closed-loop water cooling | Cool furnace body, electrode arm and other key components |
Cooling Water Flow Rate | m³/h | 50-150 | Matching equipment heat load, stable cooling effect | |
Control System | - | PLC automatic control | Real-time monitoring and adjustment of feeding, power and temperature |
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