Electric Smelting Furnace Buffer Mode for Sponge Iron Storage
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Solution Overview
Problem
The electric steel route for steel production, which uses directly reduced iron and scrap, faces inefficiencies in process coordination between electric melting furnaces and direct reduction systems, particularly in managing the production and storage of sponge iron, leading to suboptimal operational modes and energy usage.
Innovation Solution
A method that coordinates the operation of electric melting furnaces and direct reduction systems through a common control device, enabling two operating modes: regular and buffer modes. In regular mode, sponge iron is continuously melted and tapped, while in buffer mode, sponge iron is stored when collecting containers are not available, reducing energy consumption and adjusting production based on storage capacity limits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sponge iron is continuously produced in the direct reduction plant and immediately melted in the electric melting furnace, then production efficiency is improved, but system reliability deteriorates when collecting containers are unavailable
Solution Approach 1:
The patent introduces an intermediate storage position where sponge iron can be stored in advance before being fed to the melting furnace. This preliminary storage capability allows the direct reduction plant to continue operating at full capacity even when the melting furnace is temporarily unable to process material, thus resolving the contradiction between maintaining continuous production and ensuring system reliability during disruptions.
2Productivity
If the electric melting furnace operates continuously at full power, then productivity is improved, but energy consumption increases
Solution Approach 1:
The patent implements dynamic operation modes for the melting furnace including warm stand-by mode and cold stand-by mode, allowing the furnace to adjust its energy consumption based on actual production needs. When intermediate storage is sufficient, the furnace can operate at reduced power or remain in standby state, significantly reducing energy consumption while maintaining the capability to resume full productivity when needed.
3Adaptability or versatility
If an intermediate storage position is introduced for sponge iron, then system adaptability is improved, but device complexity increases
Solution Approach 1:
The patent introduces an intermediate storage position as a buffer between the direct reduction plant and the melting furnace. This intermediary component decouples the two processes, allowing them to operate independently at different rates. The storage position absorbs the complexity of coordination, providing simple feed-or-not-feed control logic while enabling sophisticated operational flexibility and adaptability in the overall system.
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 ensures efficient operation by maintaining regular production when containers are available, reducing energy usage during storage, and ensuring continuous operation of the direct reduction system with reduced sponge iron production, thereby enhancing overall system efficiency and reliability.
Implementation Method 1
the electric melting furnace and a direct reduction plant located upstream of the melting furnace... sponge iron is melted in the melting furnace to form a metallic melt
Implementation Method 2
melting furnace with arc resistance heating... heating the charge or the slag, in particular by means of the Joule effect
Implementation Method 3
A direct reduction plant is a plant in which a solid-state reaction takes place, removing oxygen from the iron ore. The reducing agents used for this purpose include coal or natural gas, particularly carbonaceous and/or hydrogenous and/or hydrocarbon-containing gases
Data Source
Figure 1
AI summary
A method for operating a plant system comprising an electric melting furnace and a direct reduction unit is described. During operation, the melt bath volume is determined. When a predetermined melt bath volume limit is reached or exceeded, a tapping operation is performed. Before tapping, the presence of a collection container for the melt is checked. If no portable collection container is available, the plant system is switched from regular operating mode to a buffer operating mode.