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YOUR SUCCESSwith SAF TECHNOLOGY YOUR SUCCESSwith SAF TECHNOLOGY

SUBMERGED-ARC FURNACE PLANTS

For more than 100 years it has been our busi-ness and tradition to work out solutions in thesubmerged-arc furnace area which assure thesuccess of our customers in the ferro alloy andnon ferrous metal industries.

The plants are characterized by state-of-the-artdesign and high-end manufacture. References allover the world demonstrate the economic suc-cess in stable and safe operation.

SMS DEMAG AG

Our company is a world-class manufacturer ofmetallurgical plant and rolling mill equipment.First-rate, high-performance products along witha customer-focused approach featuring extensiveservices form the basis of our company’s goodreputation. Equally convincing are our conceptsand plants because they provide state-of-the-arttechnology and cost effectiveness as well asquality and reliability.

SMS Demag AG becameoperational on September1, 1999, following themerger of SMS Schloe-mann-Siemag AG and themetallurgical division ofMannesmann Demag AG.As a global leader in indus-trial plant engineering, SMS Demag supplies anend-to-end product range to the steel, aluminum,copper, ferro alloy and nonferrous industries thatextends from systems forthe production of hot metalto all areas of steelmaking,continuous casting, rollingmill and tube manufactur-ing technology, as well ashot and cold strip finishingequipment.

IRONMAKING DIVISION

The submerged-arc furnace technology and relat-ed equipment is represented by the ironmakingdivision which covers the full range of productsfor ferroalloys, non-ferrous, special applicationsand pig iron.

Inline with well known SMS Demag customers-oriented approach, the division supplies turnkeysolutions, from single units up to completeplants including their control and optimizationsystems as well as any necessary engineeringservice and on-site assistance.

Submerged-Arc Furnace PlantsSMS DEMAG

SOLUTIONS forYOUR SUCCESSSOLUTIONS forYOUR SUCCESS

2

Ferro alloy tapping.

SMS Demag office in Düsseldorf/Germany.

CONTENTS

2 3 Introduction

4 5 Process know-how, metallurgical background, application

6 7 Economical success with SAF technology

8 9 SAF design criteria, specific design features

10 13 SAF design highlights

14 15 Electrical aspects

16 17 Automation and instrumentationDedusting, environment

18 19 Our service

20 21 Application ferroalloy industry

22 23 Application non-ferrous industry

24 25 Application special processesApplication pig iron/RedSmelt

26 27 Upstream and downstream equipment

28 29 Innovation for the futureReferences

30 31 Submerged-arc furnace at a glanceWhy SMS Demag?

3

OUR MISSION

To design and build complete state-of-the-art sub-merged arc furnaces, complete plants or compo-nents that will produce a product of the highestquality and consistency, delivered on a reliablebasis. The plant is designed and built in such a man-ner that quick ramp-up and safe, long-lasting opera-tion is assured.

The plant is designed operating in an environmen-tally responsible manner and produces maximumvalue for the customer and shareholders. Weachieve the best project goals in teamwork, hand-in-hand with the client. After the completion of eachjob we remain in close contact with the customer.

EXPERIENCE

and INNOVATION

The ironmaking division is the pioneer in termsof innovative submerged-arc furnace technology.Almost 500 references have been installedworldwide.The first few furnaces were commissioned in1906. By 1913, the first SAF with 6 electrodeswas operating successfully.In 1950, the first furnaces exceeded the 40000kVA power rating benchmark.During the last decade around 100 differentproducts have been processed with SAF technol-ogy for the ferro alloy, non ferrous metals, pigiron and special application industries. Each individual process requires extensive anddetailed process knowledge. The metallurgicaldepartment of our division is the foundation forthe correct design and operation of each furnace.The metallurgy determines the complete processline.

TEAMWORK/

COLLABORATION

It is our philosophy to keep good contacts withthe customer after contractual obligations are ful-filled. Furthermore, we discuss new technologi-cal challenges and common day-by-day taskswith numerous companies, universities andresearch and development institutes. Optimizingtechnological solutions with the customer is ourstrength.

DATA ACQUISITION

Data constantly acquired in newly installed plantsare analyzed to optimize the process in existingfacilities and to develop future concepts.


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PROCESS KNOW-HOW,PROCESS KNOW-HOW, metallurgical background

SAF charging Enami.

SAF in the earlytwenties.

5

DATA EVALUATION

We offer on-line assistance in running plantsworldwide, which provides us with the neces-sary information sources for optimizing process-es. Joint work with many customers all over theworld has been established.

DATA ARCHIVE

An important supporting tool is the data collec-tion within our organization. Data from the lastfew decades of almost all operating plants arestored and provide helpful process parameterson a case-to-case basis.

SOFTWARE

Metallurgical evaluations are supported byinhouse developed software which is also par-tially implemented in the automation systems.

Major customers benefits:

extensive data base availableextensive experience of industriallyoperating plants for various applicationsinnovative process developmentbased on past experience

APPLICATIONAPPLICATION

Ferro alloys

Non ferrous

Special applications

Pig iron / RedSmelt


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YOUR SUCCESS is OUR SUCCESS

We can only succeed in the long term, if ourclients are successful with our products.

Especially in the submerged-arc furnace area wecan proudly look back on numerous success sto-ries, where SMS Demag equipment assured along-lasting value for customers and sharehold-ers.

Many customers all over the world confirm thegood performance of our reliable equipment andour on-site representation/support during theplanning, engineering, installation, and commis-sioning period.

PROGRESSIVE START-UP CURVE

A progressive start-up curve on time or evenbefore the scheduled dead line is our goal foreach project.

FEASIBILITY STUDIES

We offer complete feasibility studies which inmany cases form the basis for project financing.

FINANCING OPTIONS

Reliable equipment and good plant engineeringis a key factor in financing a project. We as astrong project partner would appreciate to sup-port your project in this matter.

ECONOMIC SUCCESSECONOMIC SUCCESS with SAF technology

Success story 1SEAS Plant: Turnkey job, completion12 months after order effective date

Success story 2Enami: Turnkey job, completion after 14 months,design capacity was reached after 2 weeks

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Commissioning of SABAYEK Ferro Alloy Plant / Saudi Arabia

31.1

0.96

14.1

1.96

28.1

1.96

12.1

2.96

26.1

2.96

09.0

1.97

23.0

1.97

06.0

2.97

20.0

2.97

06.0

3.97

Furnace No. 2 – FeSi 75

Furnace No. 1 – SiMn

Furnace No. 3 – Si-Metal

Furnace No. 4 – Si-Metal

17.1

0.96


quick R.O.I.safe operation at low maintenancestrong technology supports financingstructureassured long-lasting operationprogressive start-up curveextensive reference list of satisfied customers

R.O.I. OF CERTAIN PROJECTS

In each project your investment contributes tothe project success. Quick start-ups, reliableflexible operation at low operating costs ensuresthat your investment will be returned to youwithin the shortest possible time. R.O.I.’s ofless than 2 years have been established in sev-eral projects.

FLEXIBLE FINANCIAL

ENGINEERING by SMS Demag

If required by the customer, SMS Demag canalso offer flexible financing models.

Success story 3Larco: furnace modification, 40 days fordismantling, erection and start up

Success story 4Sabayek: 4 furnaces erected andcommissioned in 2 years

GENERAL ASPECTS

During the last decades a large variety ofsubmerged-arc furnace designs has beendeveloped to suit the individual require-ments of the customer. The followingbriefly describes options which are avail-able within our division and can be cho-sen to fit perfectly to each specificprocess.

DESIGN TOOLS

Our division is equipped with advancedengineering tools such as AutoCAD2000, ProEngineer, Fluent, Ansys.

The furnaces can be supplied with sever-al features which take into account spe-cific process requirements. In the follow-ing, you will find a brief description ofspecific design features.

SAF GENERAL DESIGN

FEATURES

Open designSemi closed designClosed designSpecial design


SAF DESIGN CRITERIA,SPECIFIC DESIGN FEATURESSAF DESIGN CRITERIA,SPECIFIC DESIGN FEATURES

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Furnace charging

manual/automatichot/cold chargingbatch/continuous feedingfines charging through HES(hollow electrode system)

Furnace gas hood

roundopen/closable designhigh/low-temperature designchain/plate curtainraising/sliding doorsair/fume injection systemswater cooled steel structureinert atmosphere option

Suspended electrode column(closed furnace).

Fe-alloy.


all features available for thedesign of an optimized furnacewhich meets all processrequirements

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Furnace shell

round/rectangular designflat/curved bottomcylindrical/conical shapestationary/rotating shellopen/covered bath operationchangeable/tiltablesidewall, bottom coolingwater/air cooling

High current supply system

copper tubes/barsparallel/triangle arrangementwater/air cooled flexiblesflexibles inside/outside of the hoodinterleafed/parallel arrangement forged contact clamps

Furnace shell cover-closed roof

round/rectangular shapecylindrical/conical shapewater cooled steel structuresuspended brick roof/cast roofflat/arched shape

Electrode columns

selfbaking electrodesgraphite/prebaked electrodesextrusion electrodes/compoundelectrodeshollow electrode systemsuspended/supported designbelow above roof maintenanceclamp position below/ above the roofintensive water coolingcooling shields & protection ringvarious seal features

Supported electrode column(closed furnace). Slag cleaning furnace.

Si/FeSi furnace.

Si-metal plant – cross-section.


SAF DESIGN HIGHLIGHTSSAF DESIGN HIGHLIGHTS

10

ELECTRODE COLUMN

SMS Demag’s electrode column has beenknown for decades for its reliable and good per-formance in all submerged-arc furnace applica-tions.

A new generation of SMS Demag’s electrodecolumn ensures safe, maintenance-friendly oper-ation at minimized energy consumption.

MAIN FEATURES of the

system are:

fail-safe hydraulically actuated electrode hold-ing and slipping devicedurable contact-clamps for even electrodebaking provide highest possible energy trans-fer to the electrodereliable electrical insulation up to 1500 voltelectrode welding/nippling under operating voltageelectrode slipping under full load-currentefficient column sealing prevents exhaust offurnace gaseslittle maintenance, easy to handlecompact units, minimized space requirementsfor the systemcentral hydraulic pressure supplywear resistance assures long life even underhigher stresses and challenging environment

ELECTRODES

In general we supply all available electrodes suit-able for each individual application. The choice ofthe right electrodes is a function of economic,metallurgical aspects and the process sequence.

PRE-BAKED electrode systems

Pre-baked electrodes are available in severalgrades and sizes and can be used for all applica-tions.

SELF-BAKING electrode

systems

Self-baking electrodes lower operating costsand are usually utilized in furnaces with highercapacities in the ferro alloy, pig iron, non-ferrousand CaC2 production.

HOLLOW electrode systems

Hollow electrode systems are used to chargefines into the furnace, to lower production costsand to increase the recycling rate and thereforeprocess efficiency. 17 systems have beeninstalled in various plants.

STRUCTURAL FURNACE PARTS

with minimized electrical losses

The design of our structural furnace parts mini-mizes electrical losses caused by alternatingmagnetic fields. Components are checked byFEM calculations. In some cases, 3-5% powercould be saved with the new design features.

COOLING CONCEPTS

All cooling concepts ensure a stable, safeand long furnace campaign. Ideal balancebetween safe operation, long furnace lifeat minimized heat losses of the coolingsystem.

OPTIMIZED COOLING

CONCEPTS

Roof:

Spray coolingPanel roof cooling

Wall:

Rinse coolingSpray coolingChamber coolingChannel coolingCu-Stripe coolingTailor made cooling elements (fingers)for locally stressed areasWater cooled tapholes

Bottom:

Air coolingSpray coolingChannel cooling

TAPHOLE DESIGN

The tapholes can be offered in conven-tional design. For applications with higherstress requirements, water-cooled ele-ments are available for metal, matte andslag tapping.


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REFRACTORY CONCEPTS

The lining of each SAF is carefully select-ed. During the last decades, the refracto-ry material and lining concepts have beensteadily improved. An optimized balancebetween cooling principle and lining con-cept provides a long, safe and efficientoperation. Some furnaces showedimpressive campaigns of approx. 15-20years with one lining. Heat transfer calcu-lations (including control systems) arestandard products in our division.

RELIABLE FAILSAFE

HYDRAULIC SYSTEMS

Failsafe hydraulic systems providesmooth and reliable furnace operationand allow quick movements even ofheavy electrode columns . All hydraulical-ly operated components, i.e. electrodecolumns, furnace doors, charging chutegates, stack closures, etc. are suppliedby one central hydraulic pressure-gener-ating unit. During the last decades thesystem has been optimized and today isfailsafe and maintenancefriendly.

SAF DESIGN HIGHLIGHTSSAF DESIGN HIGHLIGHTS


best available design for SAFhigh quality manufacturecomponents based on experi-ence and company know-howon-going innovation for mostsegments

� Stripe cooling concept(horizontal option).

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Stripe cooling concept(vertical option).

Furnace roof suspendedbrick design of roundtype furnace.

Hydraulic unit.

Water cooled tapholes.�

Furnace roof suspendedbrick of rectangular furnace.


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The submerged arc furnace today is the mostwidely used technology in non-ferrous applica-tion. Plants are often located at the mines incountries where mains conditions are poorlydeveloped. The electrical concepts of SMSDemag always allow the application of sub-merged-arc furnace technology even with stronggrid restrictions.

Our company has experiences in AC and DCapplications. The technology is chosen accordingto the process requirements.

AC TECHNOLOGY

Metallurgical reactions in the submerged-arc fur-nace take place at high temperatures. Therequired electrical energy is taken from the sup-ply mains and fed into the reaction zone via avariable-ratio transformer, the high-current linesand the electrodes.

The transformer, high current lines and elec-trodes form an electrical circuit together with thereaction zone. Various arrangements and typesof connections for the transformer are available,depending on the furnace capacity and require-ments.

Our program offers AC or DC solutions, depend-ing on the local conditions and the chosenprocess. In-house engineering and intensive dis-cussions with the client determine which tech-nology is most suitable.

ELECTRICAL ASPECTSELECTRICAL ASPECTS

AC-option 1Three-phase variable-ratio transformerwith low-inductance high-current line rout-ing and delta connection at the electrodesfor round type furnace shell.

AC-option 2Three single-phase variable-ratio trans-formers arranged symmetrically aroundthe furnace, with delta connection at theelectrodes for round type furnace shell.

AC-option 3Three single-phase transformers withfixed ratio; one preceding three-phasevariable-ratio transformer and delta con-nection at the electrodes for round typefurnace shell.

AC-option 4Three single-phase variable-ratio trans-formers for 6-electrode furnaces, with in-line electrodes for rectangular type shellfurnace.

AC-option 5Three single-phase variable-ratio trans-former for 6-electrode furnaces, electrodearranged in 2 parallel lines for rectangularshaped furnace shell.


reliable failsafe operationplant installation also possiblewhen mains conditions are poorlong lasting solutionextensive AC and DC experience

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DC TECHNOLOGY

Our company developed the DC technology inthe seventies especially for electric steel plants,which were placed in locations with poorer elec-tric grid conditions. The DC technology, in combi-nation with new control systems, can reduceflicker up to 70% in comparison with convention-al AC technology.

DC furnaces are usually also characterized by alower electrode consumption. Furthermore, thistechnology can be designed in such a way thatstronger stirring and better fuming rates in the furnace can be achieved.

With respect to DC furnace technology, SMSDemag early in 1993 commissioned the first DCelectric arc furnace with billet anodes in Belgium.This furnace was at that time the world mostpowerful DC EAF with 95 MVA and 85 t tappingweight. Late in 1994 the second DC EAF of thisconfiguration with 155 t tapping weight and a 140MVA transformer rating was successfully commis-sioned in Luxembourg. Meanwhile, numerous DCEAF’s have been built or are under construction.

A SMS Demag DC submerged-arc furnace forsmelting titanium slag has been delivered toKumba in South Africa in 2002. The right anodeneeds to be determined from case to case,depending on the process requirements. All systems ensure

Optimal furnace operation Minimized electrical losses Maximizing of lifetime of bottom anode and furnace bottom

SMS Demag offer two different bottom anode systems:

Billet type anodePin type anode

High current supply lines.

High current water-coolerflexibles.

Automation is the key item in SMS Demag’sSubmerged-Arc Furnace Technology andincludes:

Control systemInstrumentationAdvanced process control.

The main concepts of SMS Demag’s solution forthe control system are:Modularity, consisting of independent controlunits allocated to different plant sections con-nected with each other to form an integratedsystem. Modularity allows the expansion of thesystem in different time steps.

Easy management: the operator is provided withthe essential information about the plant and theprocess condition by dynamic video displays,enabling him to intervene at any time with sim-ple control commands. Particular design effortsare dedicated to the engineering of the controlroom from an ergonomical point of view.

Reliability and maintainability: high availability offully automatic mode is obtainable by using inte-gral back-up configuration. Hw and sw diagnosticprograms allow any failure to be easily identified.

Besides the normal instrumentation, SMS Demag developed measuring systems for:

Metal and slag level in the furnaceMetal temperature continuously measured in the runnerCharge levelGas analysis systems

Its automation architecture is based on fully inte-grated configuration and state-of-the-art informa-

tion technology. Original well-proven mathemati-cal models are the key components of theautomation proposal:The process automation and instrumentation isone of the highlights in our program. The sys-tems were constantly upgraded. Several highlydeveloped systems also from the blast furnaceapplication have been adopted and optimizedaccordingly to ensure a stable and safe operationwith 100% control over the process at all times.

Off-line kinetic modeBurden optimization and calculation modelCharging modelFinal mass and energy balancesSAF parameter calculationLining temperature monitoringHearth erosion monitoringData reconciliationOperating guidance (expert system)

AUTOMATION and INSTRUMENTATION


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AUTOMATION and INSTRUMENTATION


automation and monitoring ensuresafe operation at low energy con-sumption and equipment wear

Control room.

17

SMS Demag’s technological know-how and in-house capabilities ensure a complete coverageof the entire submerged arc furnace plant includ-ing the down- and upstream units. Especially forclosed furnaces, the off-gas treatment is one ofthe key components because the furnace pres-sure is a critical parameter and needs to be con-trolled in a narrow range. Throughout the yearsreliable, accurate systems have been developedwhich allow this tight furnace control at highlyefficient cleaning rates.

SMS Demag also provide complete solutions forwater treatment. Basically two principles of off-gas cleaning systems are provided:

Wet System:

Desintegrator (collaboration with Theisen)

Dry System:

Bag filter suction/pressure/reversed air typeFilter dust compacting for Si-metal and FeNi-fur-naces optional (collaboration with Filtermedia)

Electrofilter:

Electro-static precipitators

Since 1972 more than 60 dry cleaning filtersystems have been installedEquivalent to approx. 1300 MVA total SAFpower ratingSince 1972 more than 30 wet cleaning systems have been installed

GAS CLEANING, DEDUSTING SYSTEMS andWATER TREATMENT

GAS CLEANING, DEDUSTING SYSTEMS andWATER TREATMENT


clean operation in an environmentallyresponsible manner

� Water treatment plant.

Filter station. �

Filter station Sabayek.

Planning:

Sound planning is the key to extensive investiga-tion into feasibility and reliability of the technicaland economic concepts. Planning includes tailor-made design for each specific customer. Wework out hand-in-hand with our clients and proj-ect partners the best specific concept, e.g. bestlocation, most ergonometric and economicalarrangement, high-quality machinery and equip-ment, optimized operation, a saleable product atmarket value. Local rules and regulations, cultur-al habits or ethic restrictions are always consid-ered in the planning phase.

Engineering:

Our engineers and technicians have always beenpioneers and explorers in submerged-arc furnaceprojects. Experienced staff with a remarkableknow -how of process, metallurgy, engineering,design, construction, commercial and economicissues are available to serve the project.

Procurement:

More than 95% of our orders come from cus-tomers outside of Germany. Thanks to this expe-rience, we can execute complex projects inkeeping with nearly all local conditions. Coopera-tion with worldwide partners and the involve-ment of local companies are our approach for asuccessful project. We find the technically mostviable solution at minimized costs. Local repre-sentatives are available for direct contact andproject support in many countries on the globe.The execution of the orders is supported byadvanced IT systems for office communicationand highly sophisticated PC application for proj-ect management, scheduling, engineering, man-ufacturing, transportation, installation and startup, training programs, operating & maintenanceinstructions and internal project archiving.

We offer services for „smaller jobs“ as wellas for complex turn key projectsCovering all necessary engineering activitiesfor modernization and new plantCoordination, consulting, supervision and sys-tems engineeringApplication of international standards and reg-ulations

Commissioning:

SMS Demag’s qualified commissioning engi-neers, process experts and metallurgists accom-pany the project during the cold and hot commis-sioning period.

Training:

Client’s operating personnel will be trained in ourhead office, at similar units abroad and on sitelocation. SMS Demag’s commissioning team isalso available to instruct client’s operating per-sonnel during the commissioning stage.


OUR SERVICEOUR SERVICE

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The following SERVICES are

supplied by SMS Demag:

De-bottlenecking study, process modelingstudies (including material handling, furnaceprocess, electrical/ mechanical items gas cleaning/ dedusting, metal/alloy and slag handling)Refractory studiesEnvironmental studiesControl system modernizationFurnace power management studiesDevelopment of measures for operating costminimizationPlanning and supply of complete plantsFeasibility studiesProject studiesFinite Element Analysis (FEA)Maintenance planningProduct optimizationFurnace dimensioning (vessel + roof)New cooling systems for capacity, lifetimeand safety improvementFurnace modelingSimulation of plant logisticsPlant commissioning (supervision)Supervision of erection

Research and development:- Smelting tests- Refractory tests- CFD analyses, numerical calculations

Installation:

SMS Demag provide experienced site staff.High-qualified erection specialists, setup installa-tion manuals, erection sequence, scheduling,site inspection and warehouse organization.Coordination of logistics, transportation & stor-age, setup of inventory and reporting systemproving completeness and proper delivery can beprovided by us. Under the direction of SMSDemag’s specialists, local companies couldsupervise the specialist manual work on theinstallation.

SMS Demag SUPERVISION and

MAINTENANCE CONTRACT:

If requested by the customer, we can also pro-vide a full service in terms of maintenance,process support, product improvement.


experienced staff for planning,engineering, procurement, com-missioning and trainingteamworkstrong background in interna-tional project execution


APPLICATION for FERROALLOYAPPLICATION for FERROALLOY

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FERRO-SILICON and SILICON METAL

The ferro-silicon grades produced in a submerged-arc furnace have Si contents of 43-96%. Gradeswith more than 96% Si are known as silicon metal.These applications stringent demands on the designand material due to high energy concentration andthe process gas formation involved. The furnaces are characterized by

encapsulated electrode columns with hydrauliccontrolcontact clamp tightening operationshort and low inductive electrical feeders

Silicon metal production units generally utilize pre-baked electrodes. SMS Demag also provide specialextrusion electrode systems for the Si-metal produc-tion to reduce operating costs.

Ferro Silicon Metal Specification:

Possible Range StandardFeSi 40 – 50 % Si FeSi45FeSi 72 – 78 % Si FeSi75FeSi 85 – 96 % Si FeSi95

FERRO-MANGANESE

and SILICO-MANGANESE

Ferro-manganese is usually available on the marketas high-carbon (6-8%C), medium-carbon (1-4%C)and low -carbon (<0.4%C) ferro-manganese prod-ucts. Alloys with high Si contents (15-20%) areknown as silico-manganese. High-carbon ferro-man-ganese and silico-manganese are produced in openor closed furnaces with stationary shell.

Ferro-manganese specification

FeMn 4 – 8 % CFeMn 1 – 4 % CFeMn < 0.4 % CSiMn 15 – 25 % Si

FERRO-CHROME and SILICO-CHROME

High-carbon ferro-chrome is produced with carboncontents of 4-8% and is usually used in AOD con-verters for the production of alloy steel grades. Dueto environmental restrictions, ferro-chrome is com-monly produced in closed stationary furnaces. Medi-um-carbon chrome alloys (0.5-2%C) and low-carbonFeCr (<0.5%C) are produced in combined processstages.Both products are produced with special slag metal-lurgy with the objective of attaining high chromeyields.

Ferro-chromium specification

FeCr 4 – 8 % CFeCr 0.5 – 2 % CFeCr < 0.5 % CSiCr 20 – 40 % C

FERRO-NICKEL

Ferro-nickel is produced in submerged-arc furnacesby chemical reduction of nickel ores. The aim is totransfer most of the nickel into the metal phase andiron into the slag phase. Good carbon distributionand a specific slag metallurgy are important to attaina high yield. Pre-heated and pre-reduced ores arehot-charged (at temperatures up to 900° C) into thefurnace.The final nickel reduction work is carried out in thesubmerged-arc furnace. Ferro-nickel furnaces areclosed stationary-type furnaces. Usually, round fur-naces are used for smaller and medium quantities,whereas large capacities are produced in rectangularfurnaces.

Ferro-nickel specification

FeNi 15 – 30% Ni

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PLANT HIGHLIGHTS

Yermakovsky, Kazakhstan

2 x 80 MVA MVA SiMn/FeMn

RDME, France

102 MVA SiMn/FeMn

SKW Becancour, Canada

1 x 38 MVA FeSi, 2 x 20 MVA Si-metal

Tulcea, Rumania

2 x 33 MVA FeMn, 43 MVA FeCr, 2 x 55 MVA FeSi

Zunyi, China

2 x 50 MVAFeSi, 1 x 30 MVA FeMn

Hunan Ferroalloy, China

30 MVA SiMn

Gulf Ferro Alloys Comp. Saudi Arabia

4x27 MVA SiMn, FeMn, FeSi, Si-Met

Eramet SLN, New Caledonia

3x48 MVA FeNi

Middleburg Steel and Alloys, South Africa

33 MVA FeCr

Minera Loma de Niquel, Venezuela

2 x 45 MVA FeNi


market leader in SAF techno-logy for ferro-alloy productionextensive process know-how reliable equipmenthigh efficiency at low energylevel

From top:1. Ferro-silicon furnace. 2. FeSi plant IMC/USA. 3. FeNi plant MineraLoma de Niquel/Venezuela. 4. FeSi/Si-metal plant CBCC/Brazil.


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APPLICATION for NON-FERROUSAPPLICATION for NON-FERROUS

NICKEL MATTE and

COPPER MATTE

The production of copper matte and nickel mattein electric furnaces is similar to the ferro-nickelprocess.The furnaces are closed, stationary-type fur-naces. Usually, round furnaces are used forsmaller to medium size quantities, whereas largecapacities are produced in rectangular furnaces.

SLAG CLEANING FURNACES

We provide several submerged-arc furnace unitsfor slag cleaning. To date, more than 20 plantshave been installed worldwide. The slag is eitherliquid-charged into the furnace or can be cold-charged in solid form via conventional feedingsystems.

For various applications such ascopper (e.g. from Teniente converter, PierceSmith converter, Outokumpu flash smelter,Noranda converter, reverts)nickelcobaltlead (e.g. from Kivcet process) and secondary leadzinctin and secondary tinplatinumpalladium

LEAD and ZINC

Zinc exits a submerged arc furnace with the gasphase. Residual metals and slag are tapped sep-arately. Submerged-arc furnaces are suitable forthe recycling of flue-dust from the steel industry(e.g. EAF-dust) and for the recycling of Pb/Zn-containing slag from BF-based zinc/lead produc-tion plants. Zinc fuming and slag cleaning fur-naces can also be offered with a DC-power supply.

PLANT HIGHLIGHTS

CEGP, France

3 MVA copper slag

Atlantic Copper, Spain

11 MVA copper slag cleaning

2 x Enami, Chile

9, 8 and 11 MVA copper slag cleaning

Codelco, Chile

14 MVA, copper slag cleaning


market leader in SAF technology for non-ferrous applicationextensive process know-how reliableequipmenthigh process efficiency at low energylevel

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CEGP, copper scraprecycling furnace.

Enami, Chile Cu-slag cleaningfurnace.

Liquid charging to SAF.

Copper matte tapping.


SPECIALPROCESSESSPECIALPROCESSES

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PLANT HIGHLIGHTS

MCB Industries, Malaysia

12 MVA CaC2

Kumba Recources, South Africa

2x36 MVA Ti-slag

SPECIAL ALLOYS

Usually, special alloys are produced in smaller unitsFe-tungsten Fe-vanadiumFe-tantalum Fe-niobium

CaC2, CaSiCalcium carbide (CaC2) is used for the production of acety-lene and calcium cyanamide. Calcium carbide and calciumsilica are also used as a desulfurization agent in the steelindustry.

TiO2-slagTitanium slag furnaces are similar to pig iron furnaces. Majorproducts are TiO2 rich slag and pig iron as a valuable “by-product”.

PhosphorusPhosphorus is usually produced in mid-size units. Phospho-rus leaves the SAF via the off-gas. Generally the furnace isoffered with a closed roof due to the pyrophoric characteris-tic of the product. Ferro-phosphorus is a by-product and canbe sold to foundries.

SLAG CLEANING and RECYCLING

The SAF converts reverts ashes to non-hazardous, non-leachable slag. The furnaces recycle steel mill waste such asmill scale, electric arc furnace dust, blast furnace flue dustand sludges to slag (and for zinc-containing reverts to zinc-

crude oxide which is collected in the filter-station). Flueashes of power plants can be also recycled with the SAF atlow costs in an environmentally friendly manner.

The SAF is suitable for cleaning various slags which accu-mulate in the ferrous and non-ferrous industry. In addition,several flue ashes are converted to a non-hazardous, non-leachable slag. Typical applications in this regards are

slag cleaning furnaces (copper, lead, zinc containing slag)waste oxide recycling furnaces for steel mill wasteswaste oxide recycling furnaces for flue ashes (frompower plants or waste incineration plants)

REFRACTORY and MINERALS

The principle of the SAF allows the melting of mineralswith high fusion temperature. Therefore, our furnaces arealso applied in various fields for refractory and mineral pro-duction. The following products can be produced withSAFs:

corundum (Al2O3) fused magnesiasolar silica basaltfused minerals mineral woolrefractory fusion furnaces

SPECIAL FURNACES

We also deliver tailor-made test furnaces in laboratory orpilot size.


all required unique concepts availablewide product range available includ-ing upstream and downstream itemsdetailed experience in variousprocesses

Corundum furnacewith electrode arms.

�

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PLANT HIGHLIGHTS

Highveld South Africa

63 MVA pig iron

Iron Dynamics, USA

38 MVA pig iron

Iron bearingmaterial(ores orresidues...)

Reductant(coal, petcoke..)Binder & Fluxes(bentonite, lime,chemicals)

GRINDER

RAW MATERIALSPREPARATION

HEATING & CHEMICAL

REDUCTION

FINAL CHEMICALREDUCTION &

SMELTING

ROTARYHEARTHFURNACE

Submerged-ArcFURNACE

MIXERGreenPellets DRI

PELLETIZER

DUST/WASTE DUST/WASTE

STEAM

HOTMETAL

SLAG

ELECTRICITY

STEAM

PowerCo-Generation


extensive knowledge in pigiron furnaceslow cost ironmaking processno lump ore charge requiredwaste recycling application

CaC2 plant Cyanamid,Canada.

� Fe-niobium tapping.

Pig iron tap. �

Flow sheet of RedSmelt concept.

APPLICATION pig iron/RedSmelt and steel mill waste recycling

The submerged arc furnace can produce hot metal up to800,000 tonnes per unit. This can be only achieved with pre-reduced iron ore pellet charge. SMS Demag provided theRedSmelt technology for pig iron production which com-bines a rotary hearth furnace for ore pre-reduction with asubmerged-arc furnace. Pig iron is also produced in a sub-merged arc furnace as a “by-product” in the Titanium slagfurnaces (e.g. at Kumba). The submerged-arc furnace iscapable of producing pig iron grades with adjustable carboncontent between 2-4.0% C. Another concept recycleswaste material from integrated steel plants and mini mills to pig iron with RedSmelt technology.

Pig iron specificationC: 2 – 4.0 %

Grinding unit. Mini sinter plant.

Pelletizing plant.


EQUIPMENT UPSTREAMEQUIPMENT UPSTREAM of the SAF

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The full range of products is available inthe areas raw material preparation, han-dling, agglomeration and processing.Besides the equipment, SMS Demagalso offer the complete automation for allcomponents which can be linked withthe main control system of the sub-merged-arc furnace unit or other destina-tions.

Raw material preparation

crushinggrindingmixingblending

Raw material agglomeration

sinteringpelletizingcold briquettinghot briquetting

Raw material handling

transportstorage

Raw material processing/

pretreatment

dryingheatingreductioncalcinationroasting

EQUIPMENT DOWNSTREAM EQUIPMENT DOWNSTREAM of the SAF

� EAF hot metal charging.

Granulation system. �

Pig casting machine.

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We also provide an extensive productrange downstream of the SAF. State ofthe art equipment for solidification, refin-ing and metal/matte/slag handling isavailable.

Granulation (static or dynamic)Hot metal charging systems to EAFPig casting machinesCasting wheelsMetal/alloy handling equipmentMetal refining equipment- Ladle refining equipment- Ladle arc reheating station- Top blown converters- AOD convertersHigh-voltage substationsKW-units


full range equipment up- anddownstream of the SAF for opti-mized process requirementsclear battery limits and respon-sibilities during project phase

Metallurgical treat-ment plants.


INNOVATIONINNOVATION for the future

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Our GOAL is to supply tomor-

row’s submerged-arc furnace

already today

SMS Demag constantly improve their fur-nace design by research and develop-ment programs combined with long-standing experience in industrial units.

The FOCUS of our current R+D

activities is on:

DC-technologycooling conceptsrefractory optimizationincrease of process efficiencylogistic improvementprocess modelingslag managementimproved tapping systemsnumerical process simulation, finite element methods

COOPERATIONS

Institute for process technology andmetal recycling in Aachen/GermanyInstitute for Ferrous Metallurgy in Aachen/GermanyTechnical University Dortmund/Ger-manyUniversity Duisburg/GermanySlag-Institute Rheinhausen/GermanyUniversidad de Chile in Santiago/ChileUniversity in Delft/NetherlandsInstitute for ore benefitiation in Othfresen/Germany

CFD simulation.

TEST FURNACE IN AACHEN/GERMANY

Technical data

Transformer connection load: 520 kVAMaximum electrode current: 5.3 kVAMaximum secondary voltage: 110 VFurnace shell diameter: 980 mmFurnace shell height: 1250 mmElectrode diameter: 150 mmElectrode hole diameter: 65 mm

Special features

DC + AC application possibleHollow electrode (optional)Dry and wet gas cleaning system attached

REFERENCES/STATISTICSREFERENCES/STATISTICS

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FERRO ALLOYS

1970 - 79 371980 - 89 421990 - today 39Total 118

NON FERROUS

1970 - 79 71980 - 89 141990 - today 16Total 37

SPECIAL PROCESSES

1970 - 79 101980 - 89 101990 - today 15Total 35

PIG IRON / RED SMELT

1970 - 79 131980 - 89 11990 - today 1Total 15

ENGINEERING STUDIES

6 – 10 studies each year1970 – today Approx. 200

PROCESS KNOW-HOW

Extensive process know-how, strongmetallurgical background based onindustrial experienceOver 500 references installed worldwideExperience in over 100 productsMarket leader for SAF technology(70% market share)

ECONOMICAL ASPECTS

Economical success with solid state-of-the-art technologyProgressive ramp up curvesQuick return on investment

DESIGN

All features availableWorldwide best electrode column systemMaintenance-friendly systemsAll types of electrodes availableSuitable cooling conceptsWater cooled tap holesSuitable refractory concept in combi-nation with balanced cooling guaran-tees long refractory life at minimumoperation costsFailsafe hydraulic systemState of the art electric systemsAutomation system ensures reliableand easy operation

ENVIRONMENT

All systems for clean operation in anenvironmentally safe manner

SERVICE

We work together with the customerin a teamExperienced team for proper planning,engineering, procurement, commis-sioning and training


SAFSAF at a glance

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Extensive experience in metallurgical plantsOverall strong partner for constructionTurn-key experienceStrong metallurgical background in iron, non-ferrous applicationContinuous innovationExtensive experience regarding upstreamand downstream technologies

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Why SMS Demag?

SMS DEMAG AG

Center of Competence Submerged-Arc Furnaces

Eduard-Schloemann-Strasse 440237 Düsseldorf, Germany

Phone: +49 (0) 211 881-6093 or 6180Telefax: +49 (0) 211 881-6980

E-mail: [email protected]: www.sms-demag.com

MEETING your EXPECTATIONS

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