Arcmon for Process Control in Silicomanganese Production: A Case Study

Arcmon is a device that is used to quantify the amount of arcing (expressed as arc power fraction) that takes place in submerged-arc furnaces (SAFs). During a trial installation on a 48-MVA SAF used for the production of SiMn, differences in arcing behavior between the three different electrodes were observed, with the amount of arcing on one electrode being significantly higher than on the other two. During the subsequent excavation of the SAF, the increased amount of arcing had been attributed to the presence of a hard build-up below the electrode. Phase chemical analysis of the hard build-up indicated that it consisted primarily of portlandite (a reaction product of calcium carbide that probably reacted with the water used to cool down the burden during excavation) and silicon carbide. In comparison, the coke-bed below one of the other electrodes consisted mainly of graphite, silicon carbide, and phases which will typically precipitate from slag upon cooling, i.e. phases expected to be present in a coke-bed. The presence of such a large build-up of carbide material is undesirable as it effectively reduces the volume of coke-bed available for the reduction reactions to occur. The study indicated that Arcmon could potentially be applied as an early warning system to identify the presence of such a build-up.