Article

SAF Submerged Arc Furnace

2 min read • January, 2017 • Procédés et fabrication › Fabrication • Dernière révision technique : 2026

Abstract

The Submerged Arc Furnace (SAF) is an advanced electrical heating system specifically designed for ferro-alloy production. This technology utilizes electrical power to facilitate pyrometallurgical smelting processes, offering superior temperature control and reduction potential adjustment capabilities. SAFs are distinguished by their high process efficiency, safe maintenance features, and ability to produce various ferro-alloys including Fe-Mn, Si-Mn, Fe-Si, and Mg-Si.

Introduction to Submerged Arc Furnace Technology

Submerged Arc Furnaces represent a cornerstone technology in modern metallurgical processing. These specialized heating systems employ electrical power to produce a wide range of ferro-alloys, offering distinct advantages in process control and operational efficiency.

Types and Classification of Arc Furnaces

Arc furnaces are categorized based on their heating methods:

Direct arc furnaces: Electric arcs burn between electrodes and the heated material
Indirect arc furnaces: Arcs burn between electrodes above the heated materials
Power supply classification: AC or DC furnaces

Energy Efficiency and Production Costs

The SAF smelting process is notably energy-intensive, with energy consumption representing a significant portion of total production costs. However, the system's efficiency in temperature control and reduction potential adjustment makes it the preferred choice for ferro-alloy production. Over time, an independent ferro-alloy industry has established itself to meet the steel industry's continuously increasing demands.

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Production Capabilities

SAFs excel in producing various ferro-alloys, including Fe-Mn (Ferro-manganese), Si-Mn (Silico-manganese), Fe-Si (Ferro-silicon), and Mg-Si (Magnesium-silicon). The production of high-purity ferro-alloys involves a combination of Submerged Arc Furnaces, Electric Arc Furnaces, and Refining Furnaces, ensuring optimal process efficiency.

Figure 1: Basic process diagram of ferro-alloy plant

Technical Features

Key technical elements include:

Hydraulically controlled electrode column system
Automated tapping and mud-gun machine systems
Optimized material charging mechanism
Water-cooled shell cover
Flexible electrical compositions for single-phase and three-phase operations

Figure 2: Schematic illustration of SAF operation

System Advantages

The SAF system provides several significant benefits:

Client-focused furnace engineering
Guaranteed equipment quality
Simple and safe maintenance procedures
High process efficiency at low energy consumption

Figure 3: Submerged Arc Furnace

References

1. A.Amadi: Modeling and optimization of three-phase Submerged Arc Furnaces (SAF), MSc thesis, University of South Africa, June 2012,
2. M.Kadkhodabeigi: Modeling of Tapping Processes in Submerged Arc Furnaces, Thesis for the degree of Philosophiae Doctor, Trondheim, May 2011
Norwegian University of Science and Technology, Faculty of Natural Sciences and Technology, Department of Materials Science and Engineering, ISBN 978-82-471-2841-1 (printed ver.), ISBN 978-82-471-2843-5 (electronic ver.) ISSN 1503-8181, Doctoral theses at NTNU, 2011:149, IMT-Report 2011:138
3. J.Kunze, R.Degel: New trends in submerged arc furnace technology, Proceedings: Tenth International Ferroalloys Congress; 1 – 4 February 2004, INFACON X: ‘Transformation through Technology’ Cape Town, South Africa, ISBN: 0-9584663-5-1
4. Ferro alloy plant, SAC Environmental&Thermal Technology, Accessed April 2016
5. All-inclusive packages for top performance, SMS group GmbH, Accessed April 2016
6. Submerged Arc Furnaces, Accessed 27 April 2016

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