Above 120T Electric Arc Furnace 63000kVA-80000kVA Eaf Furnace Ultra Large Scale
Basic Properties
Trading Properties
Product Summary
Product Details
Above 120T Electric Arc Furnace
,80000kVA Eaf Furnace
,Electric Arc Furnace 63000kVA
Product Description
I. Overview
Mega-scale steel complexes focusing on the lowest possible production cost per ton. These furnaces represent the pinnacle of EAF technology. They feature the largest shell diameters and most powerful transformers (up to 80,000 kVA or more). They are designed for ultra-high productivity, often with a fully automated process and advanced environmental control systems.
Ultra-large electric arc furnaces typically refer to those with a rated capacity of over 120 tons (especially 150 tons, 200 tons, or even larger). They are core equipment in modern "short-process" and "green steel" production. In recent years, the capacity of newly built EAF steel plants has generally increased from the 80-120 ton class to the 150-200 ton class. There are now more than 30 EAFs of 180 tons or above globally, with the maximum capacity reaching 400 tons. The largest EAF in China currently has a capacity of 220 tons.
II. Technical Specifications: 150-Ton Ultra-High Power (UHP) EAF
2.1 AC EAF Parameters (Case Study: TPCO 150T UHP AC EBT EAF)
| Parameter | Value |
|---|---|
| Rated Capacity | 150 tons |
| Shell Diameter | 7000 mm |
| Transformer Power | 90 / 100 MVA |
| Secondary Voltage Range | 300 - 890 V |
| Secondary Current Range | 64.7 - 83.6 kA |
| Graphite Electrode Diameter | 610 mm (water-spray cooled) |
| Hot Heel | ≥20 tons |
| Charging Frequency | 2 times per heat (100% cold scrap melting) |
| Electrode Regulation System | Neural network control |
| Technology Source | The 150t UHP EAF put into operation by Tianjin Pipe Corporation in 1992, a representative early case of 150-ton UHP EAF in China |
2.2 DC EAF Parameters (Case Study: Baosteel 150T UHP DC EAF)
| Parameter | Value |
|---|---|
| Tapping Weight | 150 tons |
| Hot Heel | 40 tons |
| Shell Diameter | 7300 mm |
| Hearth Diameter | 6248 mm |
| Hearth Volume | 180 m³ |
| Water-Cooled Wall Inner Diameter | 7400 mm |
| EBT Hole Diameter | 200 mm |
| Graphite Electrode Diameter | 711 mm |
| Number of Bottom Electrodes | 3 |
| Furnace Transformer Capacity | 33 MVA × 3 (total 99 MVA) |
| Center Distance of Twin Furnace Bodies | 16000 mm |
| Technical Features | Large DC EAF built during Baosteel's Phase III construction. The twin-furnace design allows one furnace to preheat while the other taps, greatly improving productivity. |
III. Key Technical Features of Ultra-Large EAFs
3.1 Ultra-High Power Input
Ultra-high power EAFs can have a transformer capacity of over 600 kVA per ton of steel, and even up to 1500 kVA. This greatly increases the heat input per unit time, significantly shortens the melting time, compresses the tap-to-tap time to less than 45 minutes, dramatically improves productivity, and reduces electrode consumption and heat loss.
3.2 Large Shell Diameter
The shell diameter of a 150-ton EAF is typically 7000-7400 mm. The larger diameter allows single-basket charging, reducing power-off time by about 2 minutes, and ensures an improved radius-to-power input ratio.
3.3 Eccentric Bottom Tapping (EBT)
EBT technology is commonly used in EAFs of 150 tons and above. It prevents slag from entering the ladle during tapping, improves steel cleanliness, and allows hot heel operation, which facilitates rapid melting of the next heat.
3.4 Advanced Electrode Control System
Modern ultra-large EAFs generally use intelligent algorithms such as neural network control to precisely regulate electrode lifting, maintaining arc stability within ±2% of the setpoint and reducing electrode consumption by 30-40%.
3.5 Water-Cooled Walls and Roof
Under ultra-high power input conditions, ultra-large EAFs must use water-cooled walls and roofs to withstand high-temperature radiation. The roof is typically a swing-away type for top charging, designed for reliability.
3.6 Long Arc-Foaming Slag Practice
Foaming slag practice enables long-arc operation, effectively transferring arc energy to the bath, improving thermal efficiency while protecting the refractory lining.
3.7 Full Automation and Intelligence
Ultra-large EAFs commonly adopt a two-level computer structure: Level 1 basic automation (PLC/electrode regulation/charging/dedusting control loops) and Level 2 process control (mathematical models/end-point prediction/power curve optimization), achieving fully automatic melting.
IV. Comparison of AC vs. DC Ultra-Large EAFs
| Comparison Item | AC EAF | DC EAF |
|---|---|---|
| Number of Electrodes | 3 | 1 (cathode) + bottom electrodes (anode) |
| Electrode Consumption | Baseline | 30-40% lower |
| Power Consumption | Baseline | 10-15% lower |
| Grid Flicker | Higher (requires SVC/SVG) | Lower (single-phase operation) |
| Temperature Distribution | Non-uniform | Uniform, less refractory wear |
| Capital Investment | Baseline | Higher (includes rectification equipment) |
| Maintenance Complexity | Baseline | Higher (complex bottom electrode maintenance) |
| Noise Level | Baseline | 10-20 dB lower |
V. Summary and Selection Recommendations
Ultra-large EAFs are key equipment for modern steel enterprises to achieve efficient, green, and intelligent production. When selecting a 150-200 ton EAF, the following factors are recommended for consideration:
| Consideration Factor | Recommendation |
|---|---|
| Product Positioning | Flat products (sheet/plate) → AC or DC; high-quality special steels → DC or high-impedance AC |
| Power Conditions | Limited grid capacity or high electricity cost → DC or high-impedance AC, equipped with SVC/SVG |
| Raw Material Mix | High proportion of scrap → consider scrap preheating and continuous feeding; high proportion of hot metal → configure oxygen lance system |
| Investment Budget | Sufficient budget → DC furnace or top-tier AC configuration; limited budget → standard AC configuration |
| Automation Level | Pursuing full automation/unmanned operation → choose top configuration with expert system and digital twin |
| Environmental Requirements | Strict emission standards → choose ultra-low emission dedusting system |
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