December 7, 2025
Improving Furnace Campaign Life in DC Electric Arc Furnaces
Given the growing trend toward refractory material procurement through comprehensive service contracts and the continuous development of electric furnace steelmaking, it is essential to adopt an integrated approach to refractory management for electric arc furnaces. The service life of a furnace lining depends not only on the design and quality of the refractory materials but also on operational practices, systematic maintenance, and overall process management.
Furnace maintenance extends beyond routine preheating, patching, and shell upkeep—it encompasses production continuity, equipment conditions, refractory selection, raw material quality, process design, and the level of scientific management and operational expertise.
The following operational measures can significantly enhance furnace campaign life:
1.1 Control of Tapping Temperature
The tapping temperature has been adjusted from above 1630°C to a target range of 1620°C ± 10°C. Strict limits are enforced to prevent high‑temperature tapping, especially for heats exceeding 1650°C. Currently, the average tapping temperature has been reduced from 1636°C at the start of the year to 1630°C, with the proportion of high‑temperature heats (tapping temperature ≥ 1650°C) kept below 10%.
1.2 Control of Tapping Carbon Content
Tapping carbon content is required to be ≥0.06%, and heats with excessive oxidation are strictly minimized. Where over‑oxidation occurs, remedial in‑furnace deoxidation must be applied promptly. For low‑carbon steel grades (finished product ≤0.06%), a new process for post‑tapping decarburization has been introduced. As a result, the average tapping carbon content has risen from 0.05% at the beginning of the year to 0.071%, and the rate of acceptable tapping carbon levels now exceeds 60%.
1.3 Slag Management
Through continuous tracking of slag composition, the timing and method of adding auxiliary materials such as lime and slag conditioners have been optimized to establish effective correlations. This adjustment, combined with full‑process foaming slag practice, helps maintain a protective slag layer on the furnace walls. The consumption of slag conditioner has increased from 4 kg/t steel at the start of the year to 5.8 kg/t steel.
1.4 Bottom Electrode Temperature Monitoring
Cooling‑water temperature and flow for the bottom electrode are monitored throughout the entire heat cycle:
- Ensure back‑pressure in the water system remains below 4.2 bar; the water treatment unit must flush the system if this value is exceeded.
- Maintain cooling‑water flow for the bottom electrode at ≥90 m³/h; filters must be cleaned if flow drops below this level.
- Investigate any bottom‑electrode temperature alarm immediately. If the cause cannot be identified, the furnace must be taken offline to inspect the hearth.
- Perform regular tracking and analysis of temperature data from all 18 monitoring points on the bottom electrode.
- Monitor the temperature of the circulating cooling water; if it exceeds 38°C, the water treatment unit must be notified to initiate air‑cooling.
By implementing these targeted operational controls, furnace life can be extended significantly, supporting stable production, reduced refractory costs, and improved overall process efficiency.
We are a professional electric furnace manufacturer. For further inquiries, or if you require submerged arc furnaces, electric arc furnaces, ladle refining furnaces, or other melting equipment, please do not hesitate to contact us at susan@aeaxa.com
