DOI 10.

1007/s11015-019-00829-4

Metallurgist, Vol. 63, Nos. 3-4, July, 2019 (Russian Original Nos. 3-4, March–April, 2019)

CALCULATION AND ANALYSIS OF THE RELATIONSHIP BETWEEN THE EFFICIENCY

AND POSITION OF ELECTRIC ARCS AND POWER CONSUMPTION IN ELECTRIC ARC
FURNACES (EAF) OF SMALLER AND LARGER CAPACITY.
PART I. CALCULATION AND ANALYSIS OF THE RELATIONSHIP BETWEEN ARC
EFFICIENCY AND POWER CONSUMPTION

A. N. Makarov1 UDC 669.187:621.186

The arc efficiency and specific power consumption were calculated and analyzed for the small (1.5 to
20 tons) and large (100 to 120 tons) capacity electric arc furnaces. In the small-capacity furnaces, the
increased specific power consumption for melting the furnace charge (475 to 500 kW ⋅ h/t) is associated
with low arc efficiency (0.55 to 0.57). In the large-capacity furnaces, the arc efficiency is 0.78 to 0.8
and specific power consumption is 360 to 375 kW ⋅ h/t.

Keywords: electric arc; furnace; steel; thermal radiation; efficiency; power consumption.

Currently, the Russian metallurgical industry includes a great number of iron and steel plants and foundries
equipped with low-power and small-capacity (1.5 to 20 t) steel-melting electric arc furnaces (EAF), some of
which require major upgrades. In the process of upgrading, it is important to choose the direction of modifying
the small-capacity EAFs to enable higher productivity, while reducing power consumption and environmental
impact. The small-capacity EAFs are characterized by an increased overall power consumption during the melt-
ing process, and specifically, by an increased amount of power required to melt the furnace charge, which con-
stitute 735 to 765 and 500 to 540 kW ⋅ h/t for DSP-5 furnaces [1–3], and 680 to 715 and 450 to 490 kW ⋅ h/t for
DSP-20 furnaces [4, 5], respectively. The specific power consumption during the melting process in today’s
high-power large-capacity melting units (DSP-120) is 375 kW ⋅ h/t [6].
As follows from the comparison of the specific power consumption of the small- and large-capacity furnac-
es, the former consume 35 to 45% more power to melt one ton of steel compared to the latter. The specific
power consumption is greater by 20 to 35% in both, older and newer small-capacity EAFs, despite the fact that
the latter are equipped with the up-to-date automated control systems (ACS), slag foaming devices, and other
melting enhancement means [7]. This phenomenon of higher specific power consumption (during melting) of
the small-capacity versus large-capacity furnaces requires analysis and subsequent interpretation.
Attempts have been made to explain this phenomenon by the larger specific surface of metal, increased heat
transfer surface area, and higher specific heat losses [7]. However, despite the increased heat losses of the large-
capacity furnaces having water-cooled walls and roof, including losses with cooling water [8], the specific pow-
er consumption of such furnaces remained about 35 to 45% lower than that of the small-capacity furnaces.
Hence, the causes of higher power consumption during melting of the small-capacity furnaces compared to
large-capacity furnaces are undetermined. To solve this problem, it is necessary to review the history and evolu-
tion of the small- and large-capacity furnaces, calculate the arc efficiency during the furnace charge melting pro-
cess, and analyze the variation of arc efficiency of the furnaces.

Federal State Budgetary Educational Institution of Higher Education “Tver State Technical University”, Tver, Russia.
1
E-mail: tgtu_kafedra_ese@mail.ru.

Translated from Metallurg, Vol. 63, No. 4 pp. 29–35, April, 2019. Original article submitted December 10, 2018.

0026-0894/19/0304-0341 © 2019 Springer Science+Business Media, LLC 341

342 A. N. MAKAROV

The calculation and analysis of the arc efficiency and energy parameters of the steel-melting process in the
furnaces of conventional and Consteel designs [9, 10] allowed to explain a paradox of the increased specific
power consumption in Consteel furnaces in comparison with the furnaces of conventional design having similar
power characteristics and capacity.
As a result of calculating and analyzing changes in the arc efficiency during the furnace charge melting pro-
cess conducted in Consteel and conventional furnaces, the following explanation of this paradox was suggested:
the average arc efficiency in Consteel furnaces is currently 13% less than that of the conventional furnaces,
while the specific power consumption of Consteel furnaces is 11% higher than that of the conventional furnac-
es [9, 10].
Let us perform a similar analysis of the evolution of small- and large-capacity furnaces and changes in the
arc efficiency during the steel-melting process. We will use the procedure to calculate and analyze the energy
parameters of the melting process suggested in Ref. [9, 10], and will calculate the arc efficiency values as well
as other energy parameters of the steel melting process in the small- and large-capacity furnaces in order to ex-
plain the increased specific power consumption in the small-capacity furnaces in comparison with large-capacity
furnaces. Let us review the technical specifications of the small-capacity (DSP-5) and large-capacity (DSP-100)
furnaces of the 1980s [4, 11] in comparison with today’s DSP-5 and DSP-120 furnaces. Technical specifica-
tions of the furnaces are provided in Table 1. The 2.8 MVA DSP-5 furnaces (1980s) are still in operation at
a number of steelmaking facilities.
In 2000s, DSP-5 furnaces were equipped with 5 MVA capacity transformers. The specific power of today’s
DSP-5 furnaces is 1000 kVA/t (see Table 1). It exceeded the specific power of today’s DSP-120 furnaces
by 20%. However, an increase in power of DSP-5 furnace without using other melting enhancement techniques
did not result in any breakthrough technical and economic characteristics of the furnace performance.
Providing DSP-5 furnaces with a 1.8 times greater capacity transformer (see Table 1) without installing gas-
oxygen burners (GOB) and slag foaming devices (SFD) resulted in 1.8 times higher productivity of the furnace,
but did not reduce the specific power consumption for melting the furnace charge and, in general, for the entire
melting process. Hence, such modernization of the furnace is not very effective. In the 1980s, the DSP-100 and
DSP-5 type furnaces operated under equal conditions without today’s devices of steel melting enhancement,
such as GOB and SFD, while running a full melting cycle, including furnace charge melting, oxidizing period,
and refining. Let us compare the technical performance characteristics of DSP-5 (2.8 MVA) and DSP-100
(45 MVA) furnaces running a full melting cycle back in the 1980s.
Such data as specific power, furnace charge melting time, and total melting time in the small- and large-
capacity furnaces were approximately the same or close in value (see Table 1). However, the specific power
consumption for melting the furnace charge and during the overall melting process in the DSP-5 furnace is 20
to 40% greater than that of the DSP-100 furnace. The walls and roof of the DSP-5 and DSP-100 furnaces are
lined. The wear of furnace walls was very different. The electric current in DSP-100 furnaces (50 kA) creates
a significant radial electrodynamic force affecting the arc, while the latter affects the metal bath via axial force,
thus, causing a deepening in the bath for the arc to drop in [11, 12]. As a result of exposure to radial electrody-
namic force and horizontal deviating electromagnetic force, the arc is partially submerged into the metal bath
and assumes an inclined position at an angle of 30 to 45° with respect to the electrode axis. As a result of such
arc position, the radiation towards the lower part of the walls (DSP-100 furnace) decreases, and the radiation
towards the medium part — increases.
In DSP-100 furnaces, the peak of the thermal radiation from the arcs is located across from them, i.e., in the
middle of the wall height counting from the metal bath level [12]. This arc radiation causes the formation of
“hot spots” on the lining in the middle of the wall height leading to lining melting. By the end of the 200-run
campaign, the refractories located across from the arcs at a half of the wall height level from the metal bath got
completely worn out exposing the furnace casing. The wear of the refractories in the lower and upper wall sections
CALCULATION AND ANALYSIS OF THE RELATIONSHIP BETWEEN THE EFFICIENCY AND POSITION OF ELECTRIC ARCS 343

Table 1
Technical Specifications of the Steel-Melting Electric Arc Furnaces

Furnace parameter DSP-5 [11] DSP-100 [11] DSP-120 [6]

Capacity G, t 5/5 100 120

Transformer capacity ST, MVA 2.8/5 45 100
Secondary voltage, V:
linear U2A (257–114)/(291–130) 486–228 1100–600
phase U2ph (148–66)/(168–75) 281–132 636–347
Arc current (max) IA, kA 6.3/6.3 50 75
Furnace charge melting time TM, h (1.1–1.8)/(1.0–1.3) 1.4–2.0 1.0
Melting time tM, h (3.5–4.5)/(2.0–3.0) 3.5–4.0 1.0
Specific power consumption, kW ⋅ h/t:
to melt furnace charge QCh 500/(480–500) 425 375
during melting process QM (650–750)/(640–750) 475–525 375
Specific power DST, kVA/t 560/1000 450 830
Pitch circle diameter dP, mm 900/900 1400 1750

Bath diameter at a slope level DB, mm 2270/2270 5400 6800

Arc-to-wall distance lW, mm 685/685 2000 2525
Lining resistance, number of melting runs:
walls nW (500–1700)/(400–1500) 200 –
roof nR 250/(220–240) 130 –

Note. DSP-5 furnace characteristics: numerator — 2.8 MVA; denominator — 5 MVA.

did not exceed 20 to 30% [12]. But since the wear of the refractories in the central portion of the walls height-
wise was 90 to 95%, the furnace had to be stopped for repairs; brickwork had to be taken apart and replaced with
the new one. The walls of DSP-100 furnaces lined with refractory brick had low resistance and could withstand,
on average, 200 melting runs.
In DSP-5 furnace, the arc current value is 6.3 kA. Such current does not cause any considerable radial and
axial forces, and does not cause any deepenings in the metal bath. The arc deviation is 15 to 20° with respect to
the electrode axis. As a result of such arc positioning in DSP-5 furnace, the peak of the thermal radiation from
the arcs is mostly focused in the lower part of the walls near the slopes [12]. After each melting run, the walls
are patched and restored using refractory powder. Since the makeup stays on top of the inclined lower sections
of the walls and slopes, and does not roll down from them, the walls get restored after each melting run, and the
resulting resistance of the wall lining enables performing 500 to 1700 melting runs. In DSP-100 furnaces, it is
344 A. N. MAKAROV

impossible to restore the walls, since the makeup powder “rolls down” from the vertical surface of the walls.
The resistance of the lined roofs of DSP-5 and DSP-100 furnaces differs slightly, since the wear of the roof lin-
ing in the small- and large-capacity furnaces occurs due to the radiation from high-temperature surface of the
electrodes [12].
Today’s high-power large-capacity DSP-120 furnaces accommodate the melting of the furnace charge,
while other process operations are performed by the secondary steelmaking units. The furnace is equipped with
gas-oxygen burners and slag foaming devices. Over the past thirty-year period, the large-capacity DSP-100 and
DSP-120 furnace parameters have increased as follows (see Table 1): specific power — doubled, arc voltage
and, respectively, arc length — by 2 to 3 times, current — by 1.5 times; the furnace charge melting time de-
creased by 1.5 to 2 times, and specific power consumption associated with such melting — by 15%. The fur-
naces were provided with water-cooled wall and roof panels, modern ACS, GOB, and SFD.
To calculate the average arc efficiency of the furnaces during melting and be able to subsequently explain
the increased specific power consumption of the small-capacity versus large-capacity furnaces, it is necessary to
have the energy balance data of the melting runs. Putting together furnace energy balances and conducting
extended, labor-consuming, and expensive experimental studies require expert teams, typically composed of
researchers from multiple organizations. For example, in the late 1970s–early 1980s, the team of the National
Research and Development Institute of Electro-Thermal Equipment (VNIIETO) conducted a 10-year-long ex-
perimental study of the energy balances of the entire series of small-, medium-, and large-capacity furnaces,
from DSP-1.5 to DSP-200. The research team comprised experts from the “Energochermet*” center, Southeast-
ern branch of “Energochermet”, Research and Development Institute of Metallurgy (NIIM), National Research
and Development Institute of Iron and Steel Industry Automation (VNIIAChM), and the staff of the plants
where the studies were conducted. The energy balances of the furnaces ranging from 1.5 to 200 t in capacity are
provided in Ref. [11]. Since electric arcs are the main source of energy in DSP-5 furnaces, and the specific
power consumption has not changed over the thirty-year period (despite a 1.8-time increase in power and
productivity), we should not expect any changes in the arc-metal and arc-slag heat transfer conditions, or furnace
arc efficiency. Therefore, it is possible to use the energy balance data during melting runs conducted in DSP-5
and DSP-100 furnaces [11], as well as energy balance data for DSP-120 furnace [6] to perform calculations and
explain the causes of the increased specific power consumption in the small-capacity versus large-capacity fur-
naces. Based on the energy balances [6, 11], the energy parameters during melting were calculated (Table 2).
As can be seen from Table 2, the specific power consumptions for melting of DSP-100 and DSP-5 furnaces
are 13% and 27% higher, respectively, compared to DSP-120 furnace. The lower specific power consumption
for melting in DSP-120 furnace is explained by using GOB and SFD in the process of furnace charge melting.
However, the specific consumption of total power for melting in DSP-120 furnace is higher than that of
DSP-100 and DSP-5 furnaces. This can be explained by comparing the energy balances of the melting peri-
od [6, 11] and the following additional calculations.
The specific usable energy (QUE ) of the melting period can be determined as the sum of heat contents of
steel (QST) and slag (QSL ):

QUE = QST + QSL. (1)

In DSP-5 and DSP-100 furnaces, the energy input includes electric power (QP), energy of Fe, Mn, and Si
oxidation reactions (QF), and furnace charge energy (QM ). Therefore, the usable arc energy (QUA ) in DSP-5
and DSP-100 furnaces is determined as the difference between the usable energy (QUE ) and the energy of oxi-
dation reactions (QF), furnace charge energy (QM ), and electric losses (ΔQE ). Considering that the efficiency

*
State Trust of the Power Equipment of the Iron and Steel Industry (Transl. note).
CALCULATION AND ANALYSIS OF THE RELATIONSHIP BETWEEN THE EFFICIENCY AND POSITION OF ELECTRIC ARCS 345

Table 2
Characteristics of the Balance Melting Runs During the Melting Period in Electric Arc Furnaces

Furnace parameter DSP-5 [11] DSP-100 [11] DSP-120 [6]

Steel grade 2Kh13 40Kh N/D
Weight, t:
metal GM 4.76 104.2 120
slag GS 0.3 4.8 5.5
Temperature, °C
metal tM 1580 1500 1620
slag TS 1590 1600 1670
Total power consumption for melting ΣQM, kW ⋅ h 2260 44310 45000
Total power consumption ΣQTot, kW ⋅ h 3013 55149 78000
Specific power consumption for melting QM, kW ⋅ h/t 475 425 375
Specific consumption of total power QTot, kW ⋅ h/t 633 529 650
Melting time, τM, h 1.33 1.47 1.0

Note. N/D — no data.

of QF and QM is equal to 1, the following can be obtained:

QUA = QUE – QF – QM – ΔQE . (2)

In DSP-120 furnace, the energy input includes electric power (QP), oxidation reaction energy (QF), natu-
ral gas energy (QNG), and coke and electrode energy (QC ). The specific usable arc energy in DSP-120 furnace
can be determined as the difference between the specific usable energy and specific usable energy of oxidation
reactions, coke and electrodes, natural gas, and electric losses:

QUA = QUE – QF – ηGOB QNG – ηC QC – ΔQE , (3)

where ηGOB and ηС are the GOB torch efficiency and the efficiency of coke and electrode oxidation reaction,
respectively.
In Ref. [10], the melting period values of the GOB torch efficiency, efficiency of coke and electrode oxida-
tion reaction, and usable arc energy (QUA ) were calculated for the balance melting run conducted in DSP-120
furnace (see characteristics in Tables 1 and 2). The QUA value constituted 277 kW ⋅ h/t. The average (over the
melting period) arc efficiency (ηAM) can be determined by dividing the specific usable arc energy by specific
power consumption (QPA):

ηAM = QUA /QPA = QUA /(QP – ΔQE ), (4)

where QP is the specific electric power input.

346 A. N. MAKAROV

The average (over the melting period) thermal efficiency of the furnace can be determined by dividing the
usable energy by the energy input (QIN):

ηТ = QUE /QIN. (5)

The energy balance data according to Ref. [6, 11], as well as the results of calculating the usable energy of
the melting period, usable arc energy, arc efficiency, and thermal efficiency are provided in Table 3.
Based on the data shown in Table 3, relationships between the average arc efficiency and specific power
consumption for melting were plotted depending on furnace capacity and enhancement of the steel melting pro-
cess (Fig. 1). Depending on furnace capacity, the average arc efficiency grows from the minimum values of
0.55–0.57 for small-capacity furnaces without GOB and SFD to 0.78–0.80 in large capacity furnaces utilizing
GOB and SFD (Fig. 1, curve I). The specific power consumption for furnace charge, on the contrary, has the
maximum value of 475 to 500 kW ⋅ h /t in the small-capacity furnaces with the lowest efficiency, and decreases
as the furnace capacity and arc efficiency increase, reaching the minimum value of 360 to 375 kW ⋅ h /t in the
large-capacity furnaces with the maximum arc efficiency (Fig. 1, curve II).
As can be seen from Table 3, heat contents of steel and slag in the studied furnaces are close in values.
A slightly higher steel and slag heat contents of DSP-120 furnace is caused by the higher temperature of steel
and slag in the DSP-120 furnace, and larger quantity of slag in the furnace. Specific losses with cooling water in
DSP-120 furnace are 3 to 7 times higher compared to DSP-100 and DSP-5 furnaces, which is associated
with the use of water-cooled wall and roof panels in DSP-120 furnace versus refractory-lined walls and roof of
DSP-100 and DSP-5 furnaces. The specific losses with flue gases of DSP-120 furnace are 3.5 times higher
compared to DSP-100 and DSP-5 furnaces due to intensive use of natural gas as a power source in GOB and
coke energy in SFD during melting process in DSP-120. The specific electric losses of DSP-120 furnace are
1.75 to 2 times lower compared to DSP-100 and DSP-5 furnaces due to an improvement over the 30-year period
of the furnace feedthroughs and reduction in the active resistance thereof by 1.75 to 2 times. The losses due to
the open roof and lining surface of the furnace constitute 9.1% and 5.9% of the energy consumption of DSP-5
and DSP-100 furnace, respectively, and are negligibly small in DSP-120 furnace. These losses are generally
associated with specific losses from the lined surfaces of the walls and roof, which are not present in DSP-120.
In DSP-5 furnace, the specific losses of energy accumulated by the lining constitute 14.5%. This parameter
does not exist in case of DSP-100 and DSP-120 furnaces. The researchers, who put together the energy balances
of the furnaces, have no explanation as to how the losses accumulated by the brickwork affect the operation of
the furnace [11]. If the furnace brickwork accumulates heat in the process of melting and transfers it to the fur-
nace charge in the beginning of melting, after the cold charge has been loaded into the furnace, then the input
part of the energy balance should contain a component accounting for the energy accumulated by the brickwork,
however, it is not present in Table 3 [11]. To solve this problem, an analytical study is required.
The specific usable energy in three studied furnaces is approximately the same, which validates the correct-
ness of the provided energy balances [6.11] and performed calculations. A slightly higher usable energy in case
of DSP-120 furnace can be explained by the higher metal temperature and larger amount and higher temperature
of slag in the furnace. The total specific losses of energy in DSP-100 furnace have the lowest value (25%),
while in DSP-120 and DSP-5 furnaces they constitute 33% and 36.5%, respectively. The 33% value of the spe-
cific energy losses in case of DSP-120 furnace can be explained by the enhancement of the steel melting process
using alternative sources of energy, natural gas, and coke, which also results in a 3.5-time increase of the specif-
ic losses with cooling gases. In DSP-5 furnace, no GOB or SFD are used, and the total specific losses consti-
tute 36.5%, which can be explained by the low average (over the melting period) arc efficiency ηAAV = 0.57.
The values of the average (over the melting period) arc efficiency of DSP-100 and DSP-120 furnaces constitute
0.67 and 0.78, respectively.
CALCULATION AND ANALYSIS OF THE RELATIONSHIP BETWEEN THE EFFICIENCY AND POSITION OF ELECTRIC ARCS 347

Fig. 1. Variation of the average arc efficiency (I) and specific poser consumption for melting (II) depending on furnace capacity and
melting process enhancement.

Table 3
Energy Balances and Average Energy Parameters of the Melting Period in Electric Arc Furnaces

Melting run parameters, incoming and consumed energy DSP-5 [11] DSP-100 [11] DSP-120 [6]

Energy input QIN (kW ⋅ h /t)/100%, including: 633/100 529/100 650/100

electric energy QE 475/80.4 425/80.3 375/58
natural gas energy QNG – – 65/10
coke and electrode energy QC N/D N/D 130/20
Fe, Mn, and Si oxidation reaction energy QF 118/18.7 99/18.8 80/12
furnace charge energy and imbalance QM 6/0.9 5/0.9 N/D
Energy consumption QEC (kW ⋅ h /t)/100%, including: 633/100 529/100 650/100
heat content of steel QSt 370/58.4 371/70.2 385/59
heat content of slag QSl 32/5.1 25/4.8 55/8
losses with cooling water ΔQW 7/1.1 18/3.4 50/8
losses with flue gases ΔQG 39/6.2 41/7.7 140/22
electrical losses ΔQE 35/5.6 42/8.0 20/3
losses due to open roof and lining surface ΔQSF 57/9.1 31/5.9 N/D
accumulated losses ΔQAL 92/14.5 N/D N/D
total losses ΣΔQ 230/36.5 132/25 210/33
usable energy QUE (% of QIN) 402/63 396/75 440/68
usable arc energy QUA (% of QE) 249/52 255/60 277/74
Average arc efficiency ηAAV 0.57 0.67 0.78
Average thermal efficiency ηT 0.64 0.75 0.68
348 A. N. MAKAROV

The average thermal efficiency has the lowest value (ηТ = 0.64) in case of DSP-5 furnace, while the high-
est (ηТ = 0.75) and medium (ηТ = 0.68) values belong to DSP-100 and DSP-120 furnaces, respectively.
The energy required to melt the furnace charge is introduced to DSP-100 furnace by means of electric arcs with
the efficiency of ηAAV = 0.67 and the energy of oxidation reactions (QF) with the efficiency equal to one.
The energy introduced to DSP-120 furnace comes from the arcs (efficiency: ηAAV = 0.78), GOB (efficiency:
0.45 to 0.55), and coke and electrode oxidation reactions (efficiency: 0.35 to 0.45) [10]. Therefore, the average
thermal efficiency of the furnace ηТ = 0.68. The introduction of energy by electric arcs is the most effective
way, while the heat from GOB and coke and electrodes is used less efficiently. However, by using the coke
powder in SFD, it becomes possible to increase the slag height and to deepen the arcs into slag, which increases
their efficiency. In DSP-100 furnaces without the use of SFD, the height of the slag layer is hSl = 100 mm and
ηA = 0.67, while in DSP-120 furnaces, hSl = 240 to 360 mm and ηA = 0.78. In DSP-5 furnaces, the height of
the slag layer is hSl = 35 mm and the arc length during the melting period constitutes 115 to 135 mm. 60 to 70%
of the arc length are not covered by slag, 2/3 of the arc power is radiated onto the wall and roof linings.
As a result, the arc efficiency at the end of the melting period is ηA = 0.35– 0.4 [12]. In the beginning of the
melting period, when arcs are burning inside a furnace charge well of DSP-5 furnace, the arc efficiency value is
ηA = 0.8 to 0.85, and average efficiency over the entire melting process is ηAAV = 0.57. As follows from the
latter, during the melting period, about 43% of the thermal radiation flux instead of targeting the furnace charge,
metal bath, and slag, hits the wall and roof linings, thus causing their heating, melting, and wear. The infor-
mation on wear and melting of the wall lining by electric arcs is described in detail in Ref. [1].
The walls of DSP-100 furnaces are made cylindrical, so when the wear and melting of the walls as a result
of exposure to electric arcs occurs in the middle of the wall height, fixing them by using spray apparatus is im-
possible, because the refractory mass rolls off the vertical surface of the walls. Therefore, the wall lining
resistance of DSP-100 furnaces was only 200 melting runs. With the transition in the 1980s to higher power
operation, furnace wall resistance dropped to 10 days and, to eliminate downtime for repairs and increase
productivity, all large-capacity furnaces got equipped with the water-cooled walls and roof.
In DSP-5 furnace, the walls are restored after each melting run with a refractory mass, so that they can with-
stand more than 500 melting runs. In the process of subsequent melting, the restored walls of DSP-5 furnace
undergo wear and melting by the arcs, and the refractory mass partially gets into slag, and partially gets carried
away with flue gases. Since electric arcs are the main source of the thermal radiation energy in DSP-5 furnaces,
and their average efficiency is ηAAV = 0.57, more than 40% of radiation power of the arcs hit the wall and roof
lining, causing wear and melting thereof. The losses, accumulated in DSP-5 furnace in connection with melting
and wear of the lining, are unrecoverable and at the maximum level compared to DSP-100 and DSP-120 furnac-
es. In DSP-100 and DSP-120 furnaces, the average arc efficiency values are ηAAV = 0.67 and ηAAV = 0.78,
respectively. This means that only 20 to 30% of the thermal radiation power of the arcs get the walls and roof,
causing wear of the lining in DSP-100 furnace and heating-up water in the water-cooled panels of DSP-120 fur-
nace, while the main usable fraction of the thermal radiation of the arcs (70 to 80% of arc power) in DSP-100
and DSP-120 furnaces irradiates the furnace charge and liquid-metal bath, causing melting and heating-up of
the latter.

CONCLUSION

The conducted analytical studies allowed to reveal the causes of the increased specific power consumption
for melting the furnace charge of a small-capacity (1.5 to 20 t) EAF compared to large-capacity (100 to 120 t)
furnaces. The compared DSP-5 and DSP-100 furnaces operated under equal conditions, without gas-oxygen
CALCULATION AND ANALYSIS OF THE RELATIONSHIP BETWEEN THE EFFICIENCY AND POSITION OF ELECTRIC ARCS 349

burners or slag foaming devices, and while running the full melting cycle. The performed calculations con-
firmed that in the small-capacity furnaces, the arc efficiency has the lowest value, which affects the possibility
of increasing their specific power consumption compared to large-capacity furnaces.

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