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Computational Modelling of Electrical Conduction in Ferroalloy Furnace Burdens

A computational model of the electrical behaviour of the burden layer in a ferroalloy furnace system is presented, focusing on ferrochromium as an example case. The model is based on the discrete element method, which calculates the mechanical interactions and resulting motion of each particle in large ensembles. A simplified set of relationships describing the melting and reaction zones around each electrode tip is included in the computational model to control the continuous consumption of particles, and it is shown how different consumption mechanisms for different types of particles can lead to the formation of reductant-rich beds and other geometric structures within the burden. A method for calculating the inter-electrode electrical resistance by constructing a network based on particle contacts is developed and used to generate quantitative estimates of inter-electrode burden conduction effects under different conditions of electrode geometry and particle consumption dynamics.