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Evolution of the Mega-Scale in Ferro-Alloy Electric Furnace Smelting

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Celebrating the Megascale

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Abstract

The historical progression in installed electric furnace smelting capacity of some 1650 calcium, chromium, manganese, nickel and silicon ferro-alloys furnaces is reviewed. Key increases in the inherent installed electrical capacity, often achieved through uprating furnaces, are identified.

Possible factors facilitating such advances are explored, including: specific process engineering and pyrometallurgical enhancements (e.g., improved control over the consistency, size and chemical form of raw materials, extents of preheating and pre-reduction delivered into the furnace; and patterns of feed distribution); furnace electrical configuration (AC or DC; immersed, submerged-, shielded- or open-arc); form of electrode (graphite, self-baking or composite); furnace configuration (circular or rectangular; closed or open and 1-, 3- or 6-electrodes); better engineering and equipment designs (e.g., high-intensity cooling) and state of furnace electrical and metallurgical control systems.

A view is presented on the prevailing state of evolution of the Mega-scale in ferro-alloy smelting and opportunities for still further improvements.

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Authors and Affiliations

  1. Anglo American Platinum Ltd, 55 Marshall Street, Johannesburg, 2107, South Africa

    Lloyd Robert Nelson

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  1. Lloyd Robert Nelson
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Editors and Affiliations

  1. Curtin University, Australia

    Eric J. Grimsey (emeritus professor of minerals engineering, chair of the institute’s Ethics Committee) (emeritus professor of minerals engineering, chair of the institute’s Ethics Committee)

  2. AusIMM, Australia

    Eric J. Grimsey (emeritus professor of minerals engineering, chair of the institute’s Ethics Committee) (emeritus professor of minerals engineering, chair of the institute’s Ethics Committee)

  3. Pyrometallurgy Division, Mintek, South Africa

    Rodney T. Jones

  4. Faculty of Engineering and Industrial Sciences, High Temperature Processing research group, Swinburne University of Technology, Australia

    Geoffrey A. Brooks (professor, leads) (professor, leads)

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Nelson, L.R. (2014). Evolution of the Mega-Scale in Ferro-Alloy Electric Furnace Smelting. In: Mackey, P.J., Grimsey, E.J., Jones, R.T., Brooks, G.A. (eds) Celebrating the Megascale. Springer, Cham. https://doi.org/10.1007/978-3-319-48234-7_3

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