1, The main uses of high carbon ferrochrome (including remanufactured ferrochrome) are:
1. Used as an alloying agent for ball bearing steel, tool steel, and high-speed steel with high carbon content, to improve the hardenability of steel, increase its wear resistance and hardness;
2. Used as an additive for cast iron to improve its wear resistance and hardness, while also giving it good heat resistance;
3. Used as chromium containing raw materials for the production of silicon chromium alloys and medium, low, and low-carbon chromium iron using slag free method;
4. Used as a raw material for electrolytic production of chromium metal;
5. Used as a raw material for smelting stainless steel by oxygen blowing method.
2. Equipment configuration plan
1. Feeding method: automatic batching in the silo, automatic feeding by the inclined bridge trolley;
2. Electrode form: self baking electrode (electrode paste);
3. Electrode lifting method: hydraulic lifting form;
4. Electrode holding brake form: dual hydraulic holding brake, with automatic fixed length pressure release, which is conducive to electrode baking;
5. Iron tapping solution: fully hydraulic opening and blocking eye machine, which is beneficial for furnace maintenance;
6. Discharge method: trolley driven (ingot mold casting);
7. Casting method: ingot mold casting, water quenching slag method, which is conducive to the recycling of waste residue to nearby cement plants;
8. Transformer configuration: Three single-phase electric furnace transformers, mainly considering long-distance transportation weight;
9. Power supply mode: primary voltage 35KV/10KV;
10. Dust removal equipment: semi enclosed low hood, without dust removal equipment. There is a dust settling device located below the main chimney;
5, Overview of Equipment Structure:
1. Adopting a fixed furnace body with 2 iron outlets.
2. Low hood structure, dual chimney smoke exhaust.
3. Self baking electrode: The electrode lifting adopts a fully hydraulic oil cylinder form, and the electrode is held tightly by a pressure ring. The conductive plate is clamped and released by a hydraulic cylinder, and manual and automatic fixed length pressure release can be achieved by using a hydraulic brake and pressure release oil cylinder.
4. Short network: It consists of a water-cooled compensator, water-cooled copper tubes, water-cooled cables, and water-cooled forged copper tiles, and adopts a new energy-saving short network structure with three single-phase transformers arranged directly.
5. The electrode distribution circle can be adjusted to accommodate changes in raw materials and processes.
6. Cooling water system: The factory is equipped with high-level water towers (or high-level water tanks) and diesel generator sets to prevent damage to components caused by sudden water outages.
7. Hydraulic system: adopts an integrated block structure, and the hydraulic medium uses water ethylene glycol (flame retardant).
8. Electric furnace transformer: It adopts a low loss energy-saving single-phase transformer with side outgoing lines, which can be overloaded by 30%. It has no-load electric voltage regulation, strong oil-water cooling, and is equipped with complete oil temperature and gas protection devices.
9. High voltage switchgear: equipped with complete detection, measurement, and relay protection for voltage, current, power, and electricity, equipped with zinc oxide lightning arresters to absorb operating overvoltage.
10. Low voltage electrical control: The control system adopts the most advanced Siemens PLC+TFT computer combination, which has the characteristics of simple operation and convenient maintenance.
3. Smelting process
Raw material preparation: Chromium ore requires high grade and low impurities, and undergoes pre-treatment such as crushing and screening to make its particle size meet the process requirements. Reducing agents such as coke, anthracite, etc. need to have high fixed carbon content, low ash content and volatile matter, and undergo drying and screening treatment. In addition, some auxiliary materials such as silica and limestone may be added as needed to adjust the composition and alkalinity of the slag.
Loading: Mix the prepared chromium ore, coke, auxiliary materials, etc. in a certain proportion and add them to the high carbon chromium iron furnace through the feeding system. When loading materials, attention should be paid to the uniformity of the fabric to avoid segregation of the furnace materials, which may affect the melting effect and product quality.
Smelting: After the electric furnace is powered on, an arc and resistance heat are generated between the electrode and the furnace material, gradually raising the temperature of the furnace material to a molten state. During the smelting process, complex physical and chemical reactions occur inside the furnace, and chromium ore is reduced to chromium by reducing agents, while combining with iron to form a high carbon chromium iron alloy. During this process, it is necessary to closely monitor and control parameters such as temperature, slag composition, and electrode position inside the furnace to ensure smooth reaction, improve chromium recovery rate, and product quality.
Ironing and casting: When the composition and temperature of high carbon chromium iron alloy meet the specified requirements, open the tapping port, put the alloy liquid into the casting package, and then cast it into chromium iron blocks or other forms of products of certain specifications. During the iron making process, attention should be paid to observing the fluidity, color, etc. of the alloy liquid to determine whether the product quality is qualified.
4. Technical Parameter
Electric furnace power: The power of high carbon chromium iron furnaces is usually relatively high, generally ranging from several thousand kilowatts to tens of thousands of kilowatts. The power level depends on factors such as production scale, furnace structure, and product requirements. Higher power can provide sufficient heat to ensure fast and efficient reactions in the furnace, improving production efficiency.
Working temperature: The working temperature inside the furnace is generally around 1600-1800 ℃. High temperature is a key condition for the reduction of chromium ore and the formation of high carbon chromium iron alloys. However, excessively high temperatures can increase energy consumption and equipment losses. Therefore, it is necessary to control the temperature within an appropriate range through reasonable process control and equipment adjustment.
Electrode current density: The electrode current density is generally controlled within the range of several amps to tens of amps per square centimeter. The appropriate current density is crucial for the normal operation of the electrode and the heating effect inside the furnace. Excessive current density can cause electrode overheating and rapid consumption; If the current density is too low, sufficient heat cannot be provided, which affects the melting efficiency.
5. Advantages and Applications
Advantages: The production of high carbon ferrochrome using a high carbon ferrochrome furnace has the advantages of high production efficiency, stable product quality, and strong adaptability to raw materials. Through reasonable process control and equipment operation, the composition and properties of the alloy can be precisely adjusted to meet the needs of different users. At the same time, the automation level of high carbon chromium iron furnaces continues to improve, which can reduce labor costs and improve production safety and reliability.
Application: High carbon ferrochrome is mainly used in the steel industry and is an important alloy additive for the production of alloy steels such as stainless steel, heat-resistant steel, and tool steel. In the steelmaking process, adding high carbon ferrochrome can improve the strength, hardness, wear resistance, corrosion resistance, and oxidation resistance of steel, and is widely used in fields such as construction, machinery manufacturing, automotive industry, aerospace, etc. In addition, high carbon chromium iron also has certain applications in the casting industry, which can be used to produce high-strength and wear-resistant castings.
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