FURNACE CHARGING

Charge Preparation:-
The charge for Electric Arc Furnaces contains non-ferrous charge and ferrous charge.
a. Non-ferrous charge (Flues an! car"uriser# :-
Non-ferrous charge consist of
(i) Calcined lime to RWF specification no. RWF//!"ECN-#/$%& ha'ing
(roadl) follo*ing composition+
- Ca, -$. min.
- !i,
/
#.0. ma1.
- !ulphur $./. ma1
- !i2e /0-&0 mm
3t is seen from past e1perience that Ra4asthan (ased calcined lime is
cleaner than 5hone (ased lime ha'ing negligi(le 6uantit) of foreign
matters li7e clin7ers8 mud8 slag8 stone etc.8 *hich imparts deleterious
effects *hile usage in steel ma7ing.
(ii) 9raphite granules (Car(uriser) to RWF !pecification No.
RWF//!"ECN-#/#$$//$$& ha'ing (roadl) follo*ing composition+
- Car(on -:. min
- !ulphur $.$0. ma1
- Ash /. ma1
- 9rain si2e $.0 to 0.; mm *ith undersi2e #$. ma1 and o'ersi2e
(upto :.$ mm) #$. ma1.
Till 5ecem(er< $08 RWF *as using Calcined "etroleum Co7e (C"C) to
RWF !pecification No.RWF//!"ECN-#/$-///$$/ ha'ing !ulphur upto
$.;. ma1 in com(ination *ith graphite po*der at 0$+0$ ratio. =o*e'er
(ecause of repeated high sulphur opening pro(lem8 use of C"C *as
restricted to /$. of total car(uriser. !ince a'aila(ilit) of Calcined
"etroleum Co7e ha'ing sulphur $.;. ma1 (ecame scarce8 use of C"C has
(een stopped.

!imilarl) 9raphite "o*der8 procured to RWF !pecification
No.RWF//!"ECN-#/$%:/#-->8 has (een found man) times to (e too
fine to ensure consistent car(on opening. As there is no price difference
(et*een graphite po*der and graphite granules no*8 RWF is using
graphite granules at present.
(iii) Calcined dolomite to RWF !pecification No.RWF//!"ECN-
#/$--//$$& ha'ing follo*ing composition.
#
- Ca, 0$-00.
- !ulphur $./. ma1
- g, >$. ma1
- !i,
/
0. ma1
Calcined dolomite is used to reduce furnace erosion? melt *ill ta7e
magnesium from dolomite instead of furnace monolithic lining.
". Ferrous Charge:-
Ferrous charge consists of rail*a) full *heels as *ell as *heels cut to &
pieces to drg no.WA"/isc/--$08 a1le end cuts coming from A1le !hop8
foundr) return (risers @ hu( cuts)8 A! (Aight elting !crap). A! is
miscellaneous rail*a) scrap consisting mainl) trac7 fittings (tie (ar8 C!T--
sleepers)8 (ogie and (ogie fittings etc. The si2es are >$$ mm ma1imum.
Recentl) offcuts of plates and sheets from 3CF are also a'aila(le. Condemned
rails cut to >$$ mm length ma1. are also used.
Ferrous scrap should (e free of dirt material and oil/grease8 ru((er items.
,il/grease and ru((er items contain high sulphur. =ence ade6uate caution
should (e gi'en (efore using scrap from diesel sheds and diesel ",= shops.
Cast iron scraps (high "hosphorus and !ulphur) and springs (ha'ing high
Chromium) should (e ta7en out from A!. !ince A! should (e *ith lo*
sulphur8 !tores Branch should put all effort in segregating the potentiall)
suspect materials from A!.
c. $uc%et preparation:-
/>.0 t capacit) clamp shell (uc7ets to RWF dra*ing no.&$# $:$/ #$#>$ are
used for charging. The charge composition is ?
(i) Non-ferrous charge (Flu1es and car(uriser) +-
Calcined lime+- #$$$ to ##$$ 7g
9raphite granules+- #&0 Cg for EAFA@B
//0 Cg for EAF C
Calcined dolomite+- /$$ Cg.
(ii) Ferrous charge+-
- *heel cut D ##.0 T
- A1le end cut D #.$ T
- A! D %.0 T
- Riser @ hu( cut D 0.0 T
- Boring chips (depending on a'aila(ilit)) D $.0 T
- Turning (ri6uettes E $.0 T
----------------------------------------
- Total D //.0 T
/
3n addition to the a(o'e four no. full *heels are directl) added in the
furnace. !o total ferrous charge 6uantit) is /% T.
!hredded scrap to Fnited !tates 3ron and !teel !crap !pecification Code
/#$//## can (e used G / to > T per heat *ith corresponding reduction
in *heel cut. Fse of shredded scrap reduces melt do*n time.
A1le cuts are used depending on the sulphur in the melt. 3n case of
repeated high sulphur opening 8 foundr) returns i.e. risers and hu( cuts
should (e used less8 rather more emphasis should (e gi'en on the use of
a1le cuts. !ulphur content in the lime also needs to (e 7ept under *atch8
Aime *ith least sulphur is preffered. ,nce high sulphur opening pro(lem
is tac7led8 foundr) returns can (e used in usual 6uantit).
(iii) !e6uence of different scrap in (uc7et is gi'en (elo*+-
Buc7et charging follo*s the charging pattern in the furnace8
- A(out $.0T of light scrap i.e.8 (oring chips8 shredded scrap and
turning (ri6uettes should (e charged at the (ottom to pro'ide
cushion to the furnace lining from the impact of the hea')
charge.
- HNo* Car(uriser ( 9raphite po*der) is added on top of calcined
lime. This is to ensure ma1imum utili2ation of car(uriser. I
- =ea') elting !crap (=!) is charged ne1t. This scrap should
(e at the centre of the furnace *ithin the "C5 of the electrodes to
a'oid scrap (ridging and electrode (rea7age due to scrap
collapse.
- Aight elting !crap (A!) is charged a(o'e =!.
- Charging is completed () adding remaining $.0T light scrap
((oring chips and shredded scrap) on top portion of the (uc7et.
Aight !crap and Aight elting !crap are charged at the top for
eas) le'eling and to facilitate smooth initiation of arc in the
furnace in the initial stages of arcing. Electrodes *ill also (ore
in to the scrap 'er) fast. This *ill a'oid damage to the roof.
Charging in furnace:-
(i) !e6uence of furnace charging *ith t*o furnace operation
- E,T Crane # goes to J" *ith molten metal
- E,T Crane / *ith 4um(o (ags ha'ing calcined line and calcined
dolomite comes and *aits 4ust south of the furnace
>
- E,T Crane > comes and charges one magnet A! in furnace as
chill. This crane goes (ac7 to lift the charging (uc7et.
- 3n the mean time E,T Crane / charges calcined lime HNo*
Car(uriser ( 9raphite po*der) is added on top of calcined lime.
This is to ensure ma1imum utili2ation of car(uriser. I and
6uic7l) goes a*a) to south to a'oid flame shoot up.
- E,T Crane > empties the charging (uc7et in the furnace.
- E,T Crane / *ith magnet in au1iliar) hoist8 le'els the scrap
(ii) !e6uence of furnace charging *ith three furnace operation
- E,T Crane # goes to J" *ith molten metal
- E,T Crane / charges # magnet of A! to chill the hot heel and
goes to south
- E,T Crane > charges % uncut *heels or # metal ca7e
- Both the Cranes go (ac7. E,T Crane / pic7s up 4um(o (ags
containing calcined lime and calcined dolomiteHNo* Car(uriser (
9raphite po*der) is added on top of calcined lime. This is to
ensure ma1imum utili2ation of car(uriser I. E,T Crane > pic7s
up charging (uc7et
- E,T Crane / comes and charges calcined lime and dolomite into
the furnace and 6uic7l) goes to*ards south to a'oid flame shoot
up.
- E,T Crane > comes and empties charging (uc7et into furnace
- E,T Crane / ha'ing magnet at au1iliar) hoist8 le'els the scrap
No* the furnace is read) for arcing.
%
&ist of 'pecifications:
!l.No. 3tem !pecification No.
#. Calcined Aime ("A No.+:#-:/;0>) RWF//!"ECN-#/$%&/#--&
/. Calcined 5olomite ("A No.+:#-:/-$/) RWF//!"ECN-#/$--//$$&
>. 9raphite 9ranules ("A No.:#-:/:-;) RWF//!"ECN-#$$//$$&
%. 9raphite "o*der ("A No.:#-:#-//) RWF//!"ECN-#/$%:/#-->
0. Calcined "etroleum Co7e ("A No.:#-&##$/) RWF//!"ECN-#/$-///$$/
;. !hredded !crap ("A No.-:-:$#%/) Code /#$//## of F! 3ron and !teel
!crap !pecification or 3! /0%--#--%8
!hredded !crap No.# (Clause 0./$)
and !hredded !crap No.> (Clause
0.//)
&. !crap Rail*a)/Rail Road Wheels ("A
No.-:##>$%0)
RWF//!"ECN-#/$-&//$$; Alt Nil
0
&ist of (ra)ings:
!l.No. 3tem 5ra*ing No.
#. Charging Buc7et (#/ Cu- capacit)) &$# $:$/ # $#>$
/. !crap Wheel Cut (& pieces) WA"/isc/--$0
;
&ist of Consu*a"les:
&
!l.No. 3tem "A No. Fnit Norm EAR Ai7el) !ources
#. Calcined Aime :#-:/;0> Cg 0%/T
of metal
-%$&$&$ a) /s. "u4a inerals "'t. Atd.8
Jodhpur To*er8 9round
Floor8 5harmnara)an Ji C
=atta8 "aota8 Jodhpur8
Ra4asthan.
() /s. Ra4asthan Aime Co.8
#$/:$#8 Teen Battichar
Rasta8 3chal7aran4i8
Colhapur8 aharastra-
%#;##0.
c) /s. J)othsna ineral
3ndustries8 5.No.--#-/>-08
!ree =ari Ni'as8
9andhinagar8 Cothapeta8
5hone8 Andra "radesh.
/. 9raphite
9ranuels
:#-:/:-; Cg -.##/T
of metal
#0:&$$& a) /s. "A Nagpur E
ineral "ul'erising ills
"'t. Atd.8 =-//8 35C8
=ingna 3ndustrial Estate8
Nagpur.
() /s. Ja)anthilal @ Co.8
9anapati Cham(ers8 /
nd
Floor8 #//-A Chittaran4an
A'enue8 Col7atta-&$$ $&>.
c) /s. =BR !ales ". Atd.8
9anapati Cham(ers8 /
nd
Floor8 #//-A Chittaran4an
A'enue8 Col7atta-&$$ $&>.
d) /s. 9raphite 3ndia Atd.8
Kish*esh*araiah 3ndustrial
Area8 White Field Road8
Bangalore E0;$ $%:.
>. Calcined
5olomite
:#-:/-$/ Cg /$$
Cgs/heat
#%:/;$$
(for &%#>
heats)
a) 5amodar Aime Chemical8
%-#-/#8 Bloc7 No.08
Trimurt) Comple18
ahad*ar Road8 Belgaum-
0-$ $$#.
() Nagar4una Chemical
3ndustries8 =.No.#$->08
5hone8 Curnool 5ist.8 A"-
0#: ///.
%. Wheel cuts -:##>$%0 T #>/heat -;>;- Lonal Rail*a)s
0. Aight elting
!crap
-:-:$$/; T %.0/heat >>>0: Lonal Rail*a)s8 3CF
: