Impact of feed mixture control on arc behaviour in direct-current arc furnace smelting of chromite – a modelling study

Unexpected excursions in electrode hoist position are occasionally observed on direct-current arc furnace plants producing ferrochromium, and are not readily explained by changes in electrical power supply or known process disturbances. One possible mechanism for this is variations in feed reductant balance altering the freeboard gas composition and, hence, the thermophysical properties of the arc plasma, changing the arc's effective electrical resistance. This hypothesis is investigated using an integrated computational modelling workflow comprising thermochemical equilibrium simulations in FactSage, plasma property calculations using the open-source minplascalc tool, and magnetohydrodynamic arc simulations using the open-source plasmaArc solver. Three reductant balance conditions were examined across a range of effective slag temperatures. Results show that while the reductant balance does influence freeboard gas composition and certain plasma properties (particularly electrical conductivity and radiation emission coefficient when lower slag temperatures are considered), these two effects act in opposing directions and largely cancel one another. Arc voltages and resistances are consequently not significantly different between reductant conditions. It is concluded that variations in feed reductant balance are unlikely to be the primary cause of the observed hoist excursion events via this mechanism, and directions for future investigation are proposed.