Operating an electric arc furnace requires a careful and systematic approach to ensure safety and efficiency. This guide will walk you through the essential steps, from pre-operation checks to post-operation maintenance.
Key Points Explained:
1. Pre-Operation Checks
- Furnace Inspection: Before starting, inspect the furnace body, cover, cooling system, and tilting mechanism to ensure they are in good condition. Check the grounding for safety.
- Tool and Equipment Check: Verify that all tools are available, dry, and correctly positioned. Ensure the electrodes are in place and functioning.
- Charge Inspection: Inspect the charge materials to ensure they meet the required specifications. Prohibit any hazardous materials like sealed boxes, tubes, or explosives.
2. Power Supply and Initial Setup
- Electrode Positioning: Raise the electrodes and conduct a thorough check to prevent short circuits. Do not power up with a load. Operate at low pressure for the first 10 minutes, then increase power.
- Safety Measures: Ensure the workplace and pit in front of the furnace are clear of water and unrelated items.
3. Melting Process
- Slag Removal: Remove the electrode voltage before removing slag. Apply gentle force to avoid splashing the steel.
- Material Addition: Add granular powder materials from the side door to prevent fire injuries. Ensure no wet materials are added.
- Oxygen Use: Maintain a safe distance from open fires when using oxygen. Handle oxygen cylinders and equipment properly. Do not use greased tools or gloves.
4. Metal Addition and Handling
- Adding Pig Iron and Ferroalloys: Preheat and dry pig iron and ferroalloys before adding them to the furnace.
- Dumping Metal Liquid: Cut off the power supply before dumping metal liquid. Ensure the pouring package is smoothly placed under the furnace tank. Do not use cold, wet objects or tubes.
5. Maintenance and Safety
- Repair and Installation: Cut off the power when repairing the furnace cover or electrodes. Use specialized equipment like trucks or cranes for electrode installation. Avoid standing on the furnace roof.
- Post-Operation Cleanup: Clean up the site promptly after work to maintain a safe and organized workspace.
6. Operational Flow
- Scrap Handling: Deliver scrap metal to a scrap bay next to the melt shop. Charge the furnace with scrap from the basket.
- Meltdown Commencement: Swing the roof back over the furnace and commence the meltdown process.
By following these detailed steps and safety measures, operators can ensure the safe and efficient operation of an electric arc furnace, minimizing risks and maximizing productivity.
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