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Estimation of Carbon Balance in Reaction Zones of a Submerged-Arc Furnace during Ferrosilicon Smelting

Based on the electrical parameters of a 20 MVA ferrosilicon furnace, a methodology of identification of characteristic ferrosilicon smelting states described as carbon excess and carbon deficiency in the reaction zones ('over-coked', 'under-coked') has been presented. Relations between the electrical parameters and assessments made by furnace operators regarding characteristic furnace states related to amounts of carbon in the reaction zones have been demonstrated. The results show that the reactive power measurements as well as the k, c3 (Andreae’s, Westly’s) parameters, provide the same information on the furnace state and have a close relation with resistivity of the current-conducting zones. Similar information on the level of carbon balance in the reaction zones is obtained from the harmonic analysis of phase voltages and currents or measurements of higher harmonic components using high-pass filters.