In this paper, we study the impact of retailers’ forecasting methods on the bullwhip effect. We consider three forecasting methods: Moving average (MA), exponential smoothing (ES), and minimum mean squared error (MMSE). We model retailers’ demand by a first-order autoregressive process. We also assume a base-stock policy for retailers’ stock replenishment. Based on Zhang (2004), we derive expressions for the bullwhip effect for each of the forecasting methods. We considered deterministic as well as stochastic lead time. We also consider multiple independent retailers. Our findings indicate that the impact of demand correlation and lead time on bullwhip effect changes with the forecasting method. However, the patterns seem to remain unaffected by the nature of lead time and the number of retailers. We also observe MMSE to outperform MA and ES when the bullwhip effect is the main concern.
{"title":"Impact of information sharing on bullwhip effect in a non-serial supply chain with deterministic lead time","authors":"Tamerat Kebede Mekonnen","doi":"10.2139/ssrn.3947016","DOIUrl":"https://doi.org/10.2139/ssrn.3947016","url":null,"abstract":"In this paper, we study the impact of retailers’ forecasting methods on the bullwhip effect. We consider three forecasting methods: Moving average (MA), exponential smoothing (ES), and minimum mean squared error (MMSE). We model retailers’ demand by a first-order autoregressive process. We also assume a base-stock policy for retailers’ stock replenishment. Based on Zhang (2004), we derive expressions for the bullwhip effect for each of the forecasting methods. We considered deterministic as well as stochastic lead time. We also consider multiple independent retailers. Our findings indicate that the impact of demand correlation and lead time on bullwhip effect changes with the forecasting method. However, the patterns seem to remain unaffected by the nature of lead time and the number of retailers. We also observe MMSE to outperform MA and ES when the bullwhip effect is the main concern.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"19 3 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-10-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128633189","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In this paper, we study the impact of retailers’ forecasting methods on the bullwhip effect. We consider three forecasting methods: Moving average (MA), exponential smoothing (ES), and minimum mean squared error (MMSE). We model retailers’ demand by a first-order autoregressive process. We also assume a base-stock policy for retailers’ stock replenishment. Based on Zhang (2004), we derive expressions for the bullwhip effect for each of the forecasting methods. We considered deterministic as well as stochastic lead time. We also consider multiple independent retailers. Our findings indicate that the impact of demand correlation and lead time on bullwhip effect changes with the forecasting method. However, the patterns seem to remain unaffected by the nature of lead time and the number of retailers. We also observe MMSE to outperform MA and ES when the bullwhip effect is the main concern.
{"title":"Impact of Forecasting Methods on the Bullwhip Effect in a Supply Chain with One Distributor and Multiple Retailers","authors":"Tamerat Kebede Mekonnen","doi":"10.2139/ssrn.3947026","DOIUrl":"https://doi.org/10.2139/ssrn.3947026","url":null,"abstract":"In this paper, we study the impact of retailers’ forecasting methods on the bullwhip effect. We consider three forecasting methods: Moving average (MA), exponential smoothing (ES), and minimum mean squared error (MMSE). We model retailers’ demand by a first-order autoregressive process. We also assume a base-stock policy for retailers’ stock replenishment. Based on Zhang (2004), we derive expressions for the bullwhip effect for each of the forecasting methods. We considered deterministic as well as stochastic lead time. We also consider multiple independent retailers. Our findings indicate that the impact of demand correlation and lead time on bullwhip effect changes with the forecasting method. However, the patterns seem to remain unaffected by the nature of lead time and the number of retailers. We also observe MMSE to outperform MA and ES when the bullwhip effect is the main concern.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"30 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-10-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"133906211","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In ERAMET Norway AS (ENO) as one of the world’s largest producers of different grades of high manganese alloys, sustainable operation has always been a priority. There are therefore continuous activities in different plants of ENO in order to reduce environmental footprints of our operations. One of the main areas of focus in such activities has been reducing diffuse emissions through design and implementation of efficient fume extraction systems based on a systematic approach. Optimal design of secondary fume extraction systems in ferroalloys industry has always been challenging. The main reason for this, is the diffuse nature of emissions which are generated from different metallurgical processes. Although design of fume capturing systems based on principles of diffuse emissions extraction is the key for high performance capturing of generated fumes from molten slag and metal but there are several operational details, practical aspects and external parameters which should be taken care of them while making an industrial design. These aspects may cause deviation of a design from its ideal conditions because of the need for necessary modifications of the design. In order to make optimal design for secondary fume extraction systems with, having full overview on practical and operational aspects, applying industrial competences, using process information and operational data and applying proper modelling methods to evaluate performance of the system at each st ep, from initial idea to final design, are of great importance. In this work, principles for design of efficient secondary fume extraction systems, main reasons of deviation from best design in the industry and ENO’s practice based on the systematic approach for making an optimal design considering all operational restrictions, is presented.
ERAMET Norway AS (ENO)作为世界上最大的不同等级高锰合金生产商之一，可持续运营一直是我们的首要任务。因此，ENO在不同的工厂不断开展活动，以减少我们运营的环境足迹。这些活动的主要重点领域之一是通过设计和实施基于系统方法的高效排烟系统来减少漫射排放。铁合金工业二次排烟系统的优化设计一直是一个具有挑战性的问题。造成这种情况的主要原因是，不同冶金过程产生的排放物具有弥漫性。尽管基于扩散排放提取原理的烟雾捕获系统的设计是高效捕获熔融渣和金属产生的烟雾的关键，但在进行工业设计时，有几个操作细节，实际方面和外部参数应该考虑到它们。这些方面可能导致设计偏离其理想状态，因为需要对设计进行必要的修改。为了对二次排烟系统进行优化设计，对实际和操作方面有全面的概述，应用工业能力，使用过程信息和操作数据，并应用适当的建模方法来评估系统从最初的想法到最终设计的每个步骤的性能，是非常重要的。在这项工作中，介绍了高效二次排烟系统的设计原则，偏离行业最佳设计的主要原因以及ENO基于考虑所有操作限制的系统优化设计方法的实践。
{"title":"Optimal Design of Secondary Fume Extraction Systems in Ferroalloys Production: from Principles to Operation","authors":"M. Kadkhodabeigi","doi":"10.2139/ssrn.3926016","DOIUrl":"https://doi.org/10.2139/ssrn.3926016","url":null,"abstract":"In ERAMET Norway AS (ENO) as one of the world’s largest producers of different grades of high manganese alloys, sustainable operation has always been a priority. There are therefore continuous activities in different plants of ENO in order to reduce environmental footprints of our operations. One of the main areas of focus in such activities has been reducing diffuse emissions through design and implementation of efficient fume extraction systems based on a systematic approach. Optimal design of secondary fume extraction systems in ferroalloys industry has always been challenging. The main reason for this, is the diffuse nature of emissions which are generated from different metallurgical processes. Although design of fume capturing systems based on principles of diffuse emissions extraction is the key for high performance capturing of generated fumes from molten slag and metal but there are several operational details, practical aspects and external parameters which should be taken care of them while making an industrial design. These aspects may cause deviation of a design from its ideal conditions because of the need for necessary modifications of the design. In order to make optimal design for secondary fume extraction systems with, having full overview on practical and operational aspects, applying industrial competences, using process information and operational data and applying proper modelling methods to evaluate performance of the system at each st ep, from initial idea to final design, are of great importance. In this work, principles for design of efficient secondary fume extraction systems, main reasons of deviation from best design in the industry and ENO’s practice based on the systematic approach for making an optimal design considering all operational restrictions, is presented.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"52 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"128175423","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Reduction of manganese and silicon oxides in smelting of silicomanganese causes significant changes in slag composition and properties, increasing the slag viscosity and decreasing diffusivities of slag components. These changes can have a strong effect on the kinetics of reduction reactions. This paper analyses effective binary diffusivity of silica and slag viscosity in the process of smelting of silicomanganese from Comilog and Wessels ores. Compositions of slag and metal phases and slag viscosity were calculated using FACTSage Version 7.2 at 1450-1600 oC. Comilog ore contained high concentration of alumina while Wessels ore had lower concentrations of Al2O3 and MnO and higher concentrations of FeO and CaO in comparison with Comilog ore. Silica effective binary diffusivity and slag viscosity were related to the ratio of non-bridging oxygens per tetrahedrally coordinated cations (NBO/T), which decreased in the process of oxides reduction. Changes in the slag composition and NBO/T ratio caused increase in the slag viscosity and decrease in the effective binary diffusivity of silica in the smelting of Comilog ore by more than an order in magnitude. In the smelting of Wessels ore, slag viscosity increased and silica effective binary diffusivity decreased by approximately 5-fold
硅锰冶炼过程中锰、硅氧化物的还原使炉渣组成和性能发生显著变化，炉渣粘度增大，炉渣组分扩散系数降低。这些变化对还原反应的动力学有很大的影响。本文分析了Comilog和Wessels矿石中硅锰冶炼过程中二氧化硅的有效二元扩散系数和炉渣粘度。使用FACTSage Version 7.2在1450-1600℃下计算炉渣和金属相的组成以及炉渣粘度。Comilog矿石的氧化铝浓度较高，而Wessels矿石的Al2O3和MnO浓度较低，FeO和CaO浓度较高。二氧化硅有效二元扩散率和炉渣粘度与非桥氧/四面体配位阳离子(NBO/T)比值有关，该比值在氧化物还原过程中减小。在Comilog矿石冶炼过程中，炉渣组成和NBO/T比的变化导致炉渣粘度升高，二氧化硅有效二元扩散系数降低一个数量级以上。在Wessels矿石冶炼过程中，炉渣粘度增大，二氧化硅有效二元扩散系数降低约5倍
{"title":"Effective Binary Diffusivity of Silica and Viscosity of Silicomanganese Slag in the Smelting of Comilog and Wessels Ores","authors":"O. Ostrovski","doi":"10.2139/ssrn.3926105","DOIUrl":"https://doi.org/10.2139/ssrn.3926105","url":null,"abstract":"Reduction of manganese and silicon oxides in smelting of silicomanganese causes significant changes in slag composition and properties, increasing the slag viscosity and decreasing diffusivities of slag components. These changes can have a strong effect on the kinetics of reduction reactions. This paper analyses effective binary diffusivity of silica and slag viscosity in the process of smelting of silicomanganese from Comilog and Wessels ores. Compositions of slag and metal phases and slag viscosity were calculated using FACTSage Version 7.2 at 1450-1600 oC. Comilog ore contained high concentration of alumina while Wessels ore had lower concentrations of Al2O3 and MnO and higher concentrations of FeO and CaO in comparison with Comilog ore. Silica effective binary diffusivity and slag viscosity were related to the ratio of non-bridging oxygens per tetrahedrally coordinated cations (NBO/T), which decreased in the process of oxides reduction. Changes in the slag composition and NBO/T ratio caused increase in the slag viscosity and decrease in the effective binary diffusivity of silica in the smelting of Comilog ore by more than an order in magnitude. In the smelting of Wessels ore, slag viscosity increased and silica effective binary diffusivity decreased by approximately 5-fold","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"97 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"130240525","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ville-Valtteri Visuri, E. Kunelius, E. Puukko, T. Fabritius
Submerged arc furnace (SAF) is a continuously operating furnace used for ferrochrome production. As the SAF is practically full of feed materials, liquid metal and slag, agglomerates may form in different parts of the furnace. The aim of this work was to set up an experimental apparatus to study the effect of temperature and atmosphere on the formation tendency of agglomerates. The agglomerates formed in the experiments were analyzed using a scanning electron microscope to study their agglomeration mechanism. The results indicate that the main agglomeration mechanisms are sintering and cold welding. Agglomerates formed by sintering exhibited both metallic and oxidic binder phases. The compression strength of the agglomerates was found to exhibit high variance but did exhibit a clear dependence on the agglomeration mechanism.
{"title":"An Experimental Study of the Formation of Surface Agglomerates in a Submerged Arc Furnace","authors":"Ville-Valtteri Visuri, E. Kunelius, E. Puukko, T. Fabritius","doi":"10.2139/ssrn.3926630","DOIUrl":"https://doi.org/10.2139/ssrn.3926630","url":null,"abstract":"Submerged arc furnace (SAF) is a continuously operating furnace used for ferrochrome production. As the SAF is practically full of feed materials, liquid metal and slag, agglomerates may form in different parts of the furnace. The aim of this work was to set up an experimental apparatus to study the effect of temperature and atmosphere on the formation tendency of agglomerates. The agglomerates formed in the experiments were analyzed using a scanning electron microscope to study their agglomeration mechanism. The results indicate that the main agglomeration mechanisms are sintering and cold welding. Agglomerates formed by sintering exhibited both metallic and oxidic binder phases. The compression strength of the agglomerates was found to exhibit high variance but did exhibit a clear dependence on the agglomeration mechanism.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"15 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"114392994","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
S. Louw, B. Belford, A. van Niekerk, R. Degel, M. Reuter
The application of DC-arc furnaces to the production of commodities such as ferrochrome, ilmenite and smelting of stainless-steel plant waste streams has progressed substantially over the last 30 years. The DC-arc furnace remains a suitable smelting unit for both consumer- & other steel plant waste products and will play a potentially significant role in the development of a circular economy. With increasing environmental legislation requirements and the associated treatment and disposal cost of consumer-, steel plant and smelter waste products, processing of these waste products is increasingly becoming more economically viable, yielding a strong business case and an overall positive environmental impact. The waste products such as spent catalysts, mill scales, steel fines and bag filter dusts often contain valuable elements and various processing routes exist to treat these waste products. The DC-arc furnace is a well-suited furnace application due to its ability to process fine materials and yield products with a higher economical value, without the need of feed-material agglomeration or high-end reductants. Inherently, the process behaviour of these furnaces is dynamic where strict metallurgical process control principles must be applied by the process team to keep the metallurgical condition of the furnace within its operational boundaries. In addition, a number of furnace design aspects further influence the control measures available to the team. This paper will focus on the application of DC-arc furnaces for fine waste stream processing, focussing on a stainless-steel waste sludge case study, with a technical focus on the inherent characteristics and design requirements of these furnaces, required to achieve a stable furnace operation.
{"title":"Technical Focus on DC-arc Furnace Application to Waste Stream Smelting","authors":"S. Louw, B. Belford, A. van Niekerk, R. Degel, M. Reuter","doi":"10.2139/ssrn.3927113","DOIUrl":"https://doi.org/10.2139/ssrn.3927113","url":null,"abstract":"The application of DC-arc furnaces to the production of commodities such as ferrochrome, ilmenite and smelting of stainless-steel plant waste streams has progressed substantially over the last 30 years. The DC-arc furnace remains a suitable smelting unit for both consumer- & other steel plant waste products and will play a potentially significant role in the development of a circular economy. With increasing environmental legislation requirements and the associated treatment and disposal cost of consumer-, steel plant and smelter waste products, processing of these waste products is increasingly becoming more economically viable, yielding a strong business case and an overall positive environmental impact. The waste products such as spent catalysts, mill scales, steel fines and bag filter dusts often contain valuable elements and various processing routes exist to treat these waste products. The DC-arc furnace is a well-suited furnace application due to its ability to process fine materials and yield products with a higher economical value, without the need of feed-material agglomeration or high-end reductants. Inherently, the process behaviour of these furnaces is dynamic where strict metallurgical process control principles must be applied by the process team to keep the metallurgical condition of the furnace within its operational boundaries. In addition, a number of furnace design aspects further influence the control measures available to the team. This paper will focus on the application of DC-arc furnaces for fine waste stream processing, focussing on a stainless-steel waste sludge case study, with a technical focus on the inherent characteristics and design requirements of these furnaces, required to achieve a stable furnace operation.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"17 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"126812387","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Laure Diaz, N. Julia, A. Amalric, G. Nussbaum, Kåre Bjarte Bjelland
From mining operations to the production of metal alloys, mining and pyrometallurgical industries generate wastes such as sludge and dust. These manganese-rich co-products are currently mostly landfilled. Landfilling has an important impact, both environmentally and economically. ERAMET manganese alloy production plants and other metal industries seek to minimize those effects by recycling such co-products in the Submerged Arc Furnace (SAF). R&D work has been carried out to address this issue through briquetting agglomeration of manganese-rich co-products. These briquettes were used as raw material in the EXCALIBUR (Experimental Campaign of the Limit of Briquette Usage in Recycling) pilot campaign. It aimed at producing High Carbon Ferro Manganese (HCFeMn) in a pilot scale SAF. This study’s main objective is to assess the process stability during briquette recycling. Briquette quality was characterized by measuring fines formation and breakage during transport. Briquette recycling’s impact on the smelting process was quantified by dust generation, furnace stability and overall process performance. These briquette recycling tests in a pilot-scale SAF are part of the feasibility study of this process at an industrial scale.
{"title":"Recycling of Mn-rich ore fines, dust and sludge briquettes in Mn alloys production","authors":"Laure Diaz, N. Julia, A. Amalric, G. Nussbaum, Kåre Bjarte Bjelland","doi":"10.2139/ssrn.3926126","DOIUrl":"https://doi.org/10.2139/ssrn.3926126","url":null,"abstract":"From mining operations to the production of metal alloys, mining and pyrometallurgical industries generate wastes such as sludge and dust. These manganese-rich co-products are currently mostly landfilled. Landfilling has an important impact, both environmentally and economically. ERAMET manganese alloy production plants and other metal industries seek to minimize those effects by recycling such co-products in the Submerged Arc Furnace (SAF). R&D work has been carried out to address this issue through briquetting agglomeration of manganese-rich co-products. These briquettes were used as raw material in the EXCALIBUR (Experimental Campaign of the Limit of Briquette Usage in Recycling) pilot campaign. It aimed at producing High Carbon Ferro Manganese (HCFeMn) in a pilot scale SAF. This study’s main objective is to assess the process stability during briquette recycling. Briquette quality was characterized by measuring fines formation and breakage during transport. Briquette recycling’s impact on the smelting process was quantified by dust generation, furnace stability and overall process performance. These briquette recycling tests in a pilot-scale SAF are part of the feasibility study of this process at an industrial scale.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"41 4","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"134092631","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
I. Kero, H. Dalaker, Karen Sende Osen, E. Ringdalen
To secure a future with the development of solar and wind energy, weather-safe roads and cities around the world, we must be able to produce metals in a safe, climate-neutral and responsible way. Obviously, we must prolong the lifespan of our materials, increase the efficiency of current processes, reuse and recycle what is already available, but that may not be enough. If we are to reach the global development goals, the world will most likely need new materials, including metals. There are many possible technologies that can help cut greenhouse gas emissions from the metallurgical industry, such as biocarbon and hydrogen as reducing agents but also electrolytic and metallothermic reduction routes and combinations of these solutions. Within each of these different themes, there are many technological possibilities. The current article gives an overview of the different alternatives to carbothermic reduction, i.e., describes the solutions which could potentially remove the need for carbon entirely. The discussion focuses on the possibilities, challenges, and the current technological barriers for these technologies to be applied to ferroalloy production.
{"title":"Some Carbon-Free Technologies for Manganese Ferroalloy Production","authors":"I. Kero, H. Dalaker, Karen Sende Osen, E. Ringdalen","doi":"10.2139/ssrn.3926069","DOIUrl":"https://doi.org/10.2139/ssrn.3926069","url":null,"abstract":"To secure a future with the development of solar and wind energy, weather-safe roads and cities around the world, we must be able to produce metals in a safe, climate-neutral and responsible way. Obviously, we must prolong the lifespan of our materials, increase the efficiency of current processes, reuse and recycle what is already available, but that may not be enough. If we are to reach the global development goals, the world will most likely need new materials, including metals. There are many possible technologies that can help cut greenhouse gas emissions from the metallurgical industry, such as biocarbon and hydrogen as reducing agents but also electrolytic and metallothermic reduction routes and combinations of these solutions. Within each of these different themes, there are many technological possibilities. The current article gives an overview of the different alternatives to carbothermic reduction, i.e., describes the solutions which could potentially remove the need for carbon entirely. The discussion focuses on the possibilities, challenges, and the current technological barriers for these technologies to be applied to ferroalloy production.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"28 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"122013639","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
P. Palovaara, Sauli Pisila, Matti Sakaranaho, Mikaela Lindvall, J. Tikka
An extensive benchmarking study was conducted to establish the design for a circular 3-electrode electric furnace of 55MW for smelting of nickel saprolitic laterite ores in the intermediate SiO2/MgO range of 2.2-2.7. The investigation was focused on “intermediate slags” in the compositional range of 15-25% FeO, 0-5% Al2O3 and a SiO2/MgO ratio of 2.2-2.7. Industrial furnace references, operating at SiO2/MgO ratios of <2.2 and >2.7, were reviewed as basis for the design. It was found that slag superheats of up to 200°C is needed when producing high grade ferronickel. The bath resistance was estimated to 9-18mOhm and the operational resistance at shielded arc conditions to 35-55mOhm (Parc/Pbath ratios of 2.0-3.0), corresponding to a secondary voltage in the range of 1400-1750V. From the risk mitigation point of view due to slag characteristics, the furnace design was not limited to operation in shielded arc mode solely, but also towards brush arc operation. At the selected hearth power density of ~200 kW/m2 a wide operation window (Parc/Pbath ratio 1.0-2.6) was found manageable to realize freeze lining control at the estimated peak sidewall heat flux of maximum 165kW/m2. A fit for purpose conservative design approach was defined, aligned with industrial references as well as the latest furnace technology developments in intensive copper cooling elements and power stabilization system, which provides a sound basis for the proposed approach.
{"title":"Benchmarking of FeNi Electric Arc Furnace Operations for Developing Furnace Design Parameters for Lateritic Ores in the Intermediate SiO2/MgO Range of between 2.2 and 2.7","authors":"P. Palovaara, Sauli Pisila, Matti Sakaranaho, Mikaela Lindvall, J. Tikka","doi":"10.2139/ssrn.3926636","DOIUrl":"https://doi.org/10.2139/ssrn.3926636","url":null,"abstract":"An extensive benchmarking study was conducted to establish the design for a circular 3-electrode electric furnace of 55MW for smelting of nickel saprolitic laterite ores in the intermediate SiO2/MgO range of 2.2-2.7. The investigation was focused on “intermediate slags” in the compositional range of 15-25% FeO, 0-5% Al2O3 and a SiO2/MgO ratio of 2.2-2.7. Industrial furnace references, operating at SiO2/MgO ratios of <2.2 and >2.7, were reviewed as basis for the design. It was found that slag superheats of up to 200°C is needed when producing high grade ferronickel. The bath resistance was estimated to 9-18mOhm and the operational resistance at shielded arc conditions to 35-55mOhm (Parc/Pbath ratios of 2.0-3.0), corresponding to a secondary voltage in the range of 1400-1750V. From the risk mitigation point of view due to slag characteristics, the furnace design was not limited to operation in shielded arc mode solely, but also towards brush arc operation. At the selected hearth power density of ~200 kW/m2 a wide operation window (Parc/Pbath ratio 1.0-2.6) was found manageable to realize freeze lining control at the estimated peak sidewall heat flux of maximum 165kW/m2. A fit for purpose conservative design approach was defined, aligned with industrial references as well as the latest furnace technology developments in intensive copper cooling elements and power stabilization system, which provides a sound basis for the proposed approach.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"226 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124185679","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Recent excavations of Norwegian medium size SiMn furnaces have revealed spectacular amounts of carbide-rich materials accumulating on the sidewalls. In an excavated furnace from Eramet Kvinesdal, producing a 19%Si silicomanganese alloy prior shutdown, the sidewall materials contained silicon carbide in addition to SiMn alloy, slag and carbon. This contrasts with the large amounts of titanium carbides found in a furnace from Ferroglobe (Glencore then) which was producing 16%Si silicomanganese. The significant volume occupied by the carbides is likely to affect the flow of materials as well as furnace operation. It is therefore meaningful to understand how and when those carbides can form, especially concerning titanium carbide given the low content of titanium (about 0.3%) in the raw materials. The present study investigates the conditions under which TiC and SiC can appear in the furnace. Slag, alloy, and gas compositions were chosen to mimic industrial charges and were reacted between 1450 and 1650 °C. The reacted samples were further analysed by electron probe microanalysis with wavelength-dispersive X-ray spectroscopy (EPMA/WDS). Thermodynamic calculations were conducted using FactSage 8.0 and used for further reflection. The results indicate that TiC was formed by both precipitation and chemical reaction.
{"title":"Carbide formation and accumulation in SiMn furnaces","authors":"Vincent Canaguier, Jonas E Gjøvik, E. Ringdalen","doi":"10.2139/ssrn.3926154","DOIUrl":"https://doi.org/10.2139/ssrn.3926154","url":null,"abstract":"Recent excavations of Norwegian medium size SiMn furnaces have revealed spectacular amounts of carbide-rich materials accumulating on the sidewalls. In an excavated furnace from Eramet Kvinesdal, producing a 19%Si silicomanganese alloy prior shutdown, the sidewall materials contained silicon carbide in addition to SiMn alloy, slag and carbon. This contrasts with the large amounts of titanium carbides found in a furnace from Ferroglobe (Glencore then) which was producing 16%Si silicomanganese. The significant volume occupied by the carbides is likely to affect the flow of materials as well as furnace operation. It is therefore meaningful to understand how and when those carbides can form, especially concerning titanium carbide given the low content of titanium (about 0.3%) in the raw materials. The present study investigates the conditions under which TiC and SiC can appear in the furnace. Slag, alloy, and gas compositions were chosen to mimic industrial charges and were reacted between 1450 and 1650 °C. The reacted samples were further analysed by electron probe microanalysis with wavelength-dispersive X-ray spectroscopy (EPMA/WDS). Thermodynamic calculations were conducted using FactSage 8.0 and used for further reflection. The results indicate that TiC was formed by both precipitation and chemical reaction.","PeriodicalId":325178,"journal":{"name":"EngRN: Production Engineering (Topic)","volume":"10 33 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-09-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"124732444","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
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