1. Mix Each Batch Uniformly
Each batch of materials must be mixed evenly before being added to the furnace. No random addition is allowed. The proportion of each batch is calculated based on the chemical reaction principle of ferrosilicon smelting, the composition of the raw materials used, and the actual situation. Therefore, the composition of each batch added to the furnace must comply with the batch ratio. Uniform mixing of the charge is an important operating condition to ensure normal reaction in the furnace.
If the charge is not uniformly mixed or is added selectively, this is what is commonly known as biased charging. The result is excess silica or excess coke in local areas of the furnace, both of which are unfavorable: the reaction in the furnace does not proceed smoothly, and the furnace condition worsens.
2. Add Materials in Small Batches Continuously
Furnace materials should be added into the furnace continuously in small batches. This not only makes it easy to control the height of the material surface, but also makes the composition and distribution of the added charge more uniform.
3. Control the Material Surface Height
The height of the material surface must be properly controlled. If the material surface height is too high, the electrode will rise. If the material surface is too low, the material will collapse. Both conditions prevent full utilization of the heat and have an adverse impact on the furnace condition.
Frequently Asked Questions
Why is uniform mixing essential? Non-uniform charging causes local excess of silica or coke, disturbing reduction and worsening furnace conditions.
Why add materials in small continuous batches? It controls the material surface height and keeps the charge composition and distribution uniform.
What happens if the material surface is too high or too low? Too high raises the electrode; too low causes material collapse; both waste heat and harm furnace operation.
Why must the batch ratio be calculated before charging? The batch ratio is derived from the chemical reaction principle of ferrosilicon smelting and the composition of the raw materials in use; the charge added to the furnace must match this ratio so the reduction proceeds normally.
What is biased charging and why is it harmful? Biased charging means the charge is added selectively instead of being uniformly mixed, creating local excess of silica or coke that disturbs the reduction reaction and progressively worsens furnace conditions.
