Ferro-alloy Slag Foaming via Polymer Segmentation
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Solution Overview
Problem
Existing methods for producing ferro-alloys in electric arc furnaces face challenges with contamination and inefficiencies due to the use of agglomerated carbon-containing polymers, which can produce noxious gases and interfere with the production process, and there is a need for improved slag foaming and reducing agents.
Innovation Solution
A method involving the controlled supply of a mixture of unagglomerated and agglomerated carbon-containing polymers, along with another carbon source, during specific phases of the furnace operation to enhance slag foaming and reduce contaminants, including the use of materials handling systems for efficient delivery and heat control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If agglomerated carbon-containing polymers are used as slag foaming agents, then the polymer can be supplied to the furnace, but it produces noxious gases and interferes with ferro-alloy production
Solution Approach 1:
The patent segments the carbon-containing polymer supply into two distinct forms: unagglomerated polymer (which combusts cleanly) and agglomerated polymer mixed with carbonaceous material (which prevents noxious gas formation). This segmentation allows each form to serve its specific function without the harmful effects of the other.
Solution Approach 2:
The patent creates a composite material by mixing agglomerated carbon-containing polymer with carbonaceous material (such as coke, coal, or carbon black). This composite prevents the formation of noxious gases by ensuring complete combustion through the added carbon source, while still maintaining the slag foaming capability of the polymer.
2Object-generated harmful factors
If unagglomerated carbon-containing polymer is supplied to the furnace, then it combusts and produces carbonaceous residue for slag foaming, but the supply system becomes complex
Solution Approach 1:
The patent makes the carbon-containing polymer supply system multi-functional by using the same polymer source for both combustion (to produce heat and carbonaceous residue) and slag foaming. The unagglomerated polymer serves dual purposes: combusting to generate carbon for the slag foaming reaction and directly contributing to slag foaming when supplied as unagglomerated material.
Solution Approach 2:
The patent merges the functions of slag foaming and carbon supply by using unagglomerated carbon-containing polymer that performs both roles simultaneously. The polymer combusts to produce carbonaceous residue that oxidizes to cause slag foaming, eliminating the need for separate foaming agents and simplifying the overall material supply system.
3Productivity
If carbon-containing polymer is used as reducing agent and recarburiser, then it can replace traditional carbon sources, but contamination and pollutants increase
Solution Approach 1:
The patent changes the physical state parameter of the carbon-containing polymer from agglomerated to unagglomerated form. This parameter change ensures complete combustion and prevents the formation of noxious gases, allowing the polymer to function as an effective reducing agent and recarburiser without introducing contaminants or pollutants into the ferro-alloy production process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach speeds up the slag-foaming process, reduces electricity consumption, decreases greenhouse gas emissions, lowers production costs, and improves furnace productivity by optimizing the 'tap-to-tap' time, while potentially diverting waste polymers from landfills.
Implementation Method 1
establishing an arc between an electrode or electrodes of the furnace and the solid feedstock charge and generating heat in the furnace and melting the solid feedstock charge
Implementation Method 2
the unagglomerated carbon-containing polymer is charged into an electric arc furnace such that it at least partially combusts and produces a carbonaceous residue
Implementation Method 3
the carbonaceous residue then oxidises to cause slag foaming
Data Source
Figure 1
AI summary
A method for producing a ferro-alloy, such as steel, in an electric arc furnace or other suitable metallurgical furnace is disclosed. The method comprises supplying a mixture of (a) a carbon-containing polymer that is capable of acting as a slag foaming agent and (b) another source of carbon into the furnace during at least a part of a power-on phase of the method. A metallurgical furnace is also disclosed.