Submerged Arc Furnaces (SAF) have been used in many metallurgy areas of for over 100 years

The application areas for SAF include for example production of:

 -          ferro silicon,

 -          silicon metal

 -          ferro chrome

 -          ferro nickel

 -          ferro manganese

 -          silico manganese

 -         calcium carbide

 -          and others

  and they are used for

 -          copper slag cleaning

 -          as well as waste recycling.

In opposite to arc furnaces in the steel industry, where the heat for melting comes from an open arc, the electrodes of a SAF are immersed in the raw materials. The current which flows through the resistance of the burden heats the material in the furnace up. The electric energy which is converted into heat can be controlled by the voltage between the electrode and the furnace heart, the electrode current and the resistance of the material.

A conventional SAF consists of a furnace shell (with a cover or hood), electrodes (3 sometimes 6), furnace transformer (1 or 3), high current lines between the transformer(s) and the electrodes. Of course, a raw material feeding system and tapping equipment belongs also to a furnace.

For the efficiency of the furnace production and the economical result is important to have a reliable furnace design and furnace equipment, the right choice of the raw materials and the furnace control system.

Special electrode controllers are needed to optimize the process. The right parameterization of the controllers is as important as the controller itself.

One needs a lot of experience to design, to build and to operate a SAF plant. Not only the furnace itself as the key part is important also the raw material storage, mixing and transportation plant, the tapping and casting area, the primary and secondary dedusting plant as well as the cooling water system must be considered.

All these systems must be provided with electrical energy. The design of a reliable electrical power system including power factor compensation needs to be taken care of. Special care must be taken to the furnace transformer(s) regarding power range, secondary voltage range and secondary current and cooling system.

Beside the electrical power system also the control systems, measuring systems and an HMI system with data monitoring and storage of all plant parts need to be well designed.

Each product has special needs on the furnace, the equipment, the auxiliary plants, raw materials and the control.