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Electric Furnaces In The Iron And Steel Industry By Dipl. Ing. W. Bodenhauser
Electric Furnaces In The Iron And Steel Industry By Dipl. Ing. W. Bodenhauser, E.E. Chief Engineer, Electric Furnace Department, REisen Und Stahlwerke, Vglklingen, Germany Chief Engineer, Gesellschaft Fur Elektrostahlanlagen, M. B. H., Berlin And I. Schoenawa Formerly Operating Engineer REisen Und Stahlwerke
From Advance Sheets of the Second German Edition
Authorized Translation and Additions
by C. H. VOM BAUR, E.E.
FIRST EDITION
FIRST THOUSAND
NEW YORK
JOHN WILEY & SONS
LONDON: CHAPMAN & HALL, LIMITED
1913
Hard Cover
Copyright 1913
419 pages
Indexed
TITLE PAGE is loose
PREFACE TO THE EDITION IN ENGLISH
THE preparation of this work in English was undertaken in the belief that electric furnaces for the iron and steel industry would have their greatest future on the North American Continent. Especially is this true of furnaces making electric steel. Specifications are daily becoming stricter for steel rails, steel castings, and tool steel. Electric steel rails, costing but little more than the ordinary kind, are found to be unbreakable in service, when laid beside open hearth and Bessemer rails. In these latter, scores of breakages have occurred in one season. The future of electric steel rails consequently seems assured.
Electric steel castings have also been on the market for the past four years. They are looked upon with favor alike by the foundryman and the customer, not only because the highest class of steel may be made from the cheapest raw material, but also because of the high percentage of good castings and their freedom from blow-holes.
The ability to make homogeneous tool steel, free from gases, and at low cost, brought the electric furnace into commercial use over a decade ago. In this field it promises to displace completely the old and small crucible pot which has been in use since the year 1740.
With these three principal fields now open to electric furnace products, it cannot be long before all other domains in the use of steel will be invaded. The cost of producing electric steel is lower now than that of the crucible process, or of the small converter process, and even less than that of the open hearth process, as practised with ro-ton furnaces or under. A success can, therefore, be confidently predicted for electric furnaces and their manufacture of iron and steel.
CONTENTS
PART I
ELECTRIC FURNACES, THEIR THEORY, CONSTRUCTION,
AND CRITICISM
CHAPTER I
HISTORICAL
PAGE
Some data relating to the development of electrical engineering,1
Tests of Davy and Pepys, 3
Suggestions by Wall 4
by Pichon, 4
by William von Siemens, 5
by de Laval, 6
by Taussig, 8
The electric furnace of Stassano, 8
of H, 9
of Kjellin,9
Report of the Canadian Commission under Dr. Haanel 9
The electric furnace of Girod, 10
of R, to
of Gr, Lindblad & Stalhane Io
CHAPTER II
SOME LAWS AND FUNDAMENTAL PRINCIPLES OF ELECTRICITY
Ohm's Law, I1
Resistance of a conductor, it
Units of measurement: Ampere, volt, ohm, 12
Temperature coefficient, 13
Conductors of the second class, 15
Series connection 16
Parallel connection, 17
I. Kirchoff's Law, 19
Combination resistances, 20
Arithmetical example, 21
Joule's Law, ~3
The derivation of heat generated, ~3
of power, 24
of work, ~5
CHAPTER III
EFFECTS OF THE ELECTRIC CURRENT
The action of heat,
I. Direct resistance heating,
Gin, Electric furnace of,
Arithmetical example therefore,
Current density, permissible in copper conductors
2. Induction heating,
3. Indirect resistance heating,
Borchers, Laboratory furnace of,
Heraus, Laboratory furnace of,
Girod, Crucible furnace of,
Helberger, Crucible furnace of,
4. Arc heating,
Chemical action,
Motor effect
Action of two magnets upon each other,
Lines of force of a current-carrying conductor,
Direction of lines of force,
Action between a magnet and electrical conductor,
of two electrical conductors upon each other,
Lines of force of coils,
Pinch effect,
CHAPTER IV
POWER FACTOR (cos C') AND ALTERNATING CURRENT THEORY IN GENERAL
Periodicity, frequency, cycle, 47
Line diagram, 47
Angular velocity, 48
Induction, induced currents,
49
Self-induction, current of self-induction5o
Phase difference, 51
Vector diagram, 5!
Coefficient of self-induction,
52
Apparent resistance,
54
Power in alternating current circuits, 57
factor, 58
Losses on account of induction phenomena, 59
Eddy or Foucoult currents, 59
Hysteresis losses, 6o
Three phase current, polyphase current, 6o
Star or Y connection, 61
Delta connection 62
CHAPTER V
GENERAL CONDITIONS FOR THE OPERATION OF ELECTRIC FURNACES
PAGE
Advantages of electric furnaces, 65
Demands made of an ideal electric furnace, 66
Influence of the kind of current, 68
of the frequency, 70
of changes in the load 71
Regulating power of the furnace temperature, 72
Electric efficiency,
Furnace and hearth arrangement,
Influence of electric heating, Circulation of the molten metal, Influence of water cooling,
CHAPTER VI
THE ARC FURNACES IN GENERAL
The arc, 77
Radiation furnaces, 79
Combined arc and resistance furnaces, 79
The electrodes of arc furnaces, 8o
Current density in electrodes, 82
Efficiency of electrodes, 84
Burning away of electrodes, 89
Electrode consumption, 89
coverings, 97
cooling, 99
regulation, 102
Thury, regulator, 102
CHAPTER VII
THE STASSANO FURNACE
Stassano shaft furnace 107
hearth furnace, 108
rotating furnace, 108
Comparison with an ideal furnace, 116
Installation costs, 120
Issuing of licenses, 120
CHAPTER VIII
THE HFURNACE
Historical, 12I
The Furnace, 122
Comparison with an ideal furnace, 133
Installation costs, 141
Issuing of licenses, 143
CHAPTER IX
THE GIROD FURNACE
PAGE
Historical,144
The145
furnace,
Comparison with an ideal furnace, 151
of electrode cross-section with a Girod and H,.154
Installation costs,157
Issuing of licenses, 159
CHAPTER X
THE INDUCTION FURNACE IN GENERAL
Principle of the transformer, 16o
of the induction furnaces161
Cylinder winding, tube winding, disk winding, 165
Suggestions by de Ferranti, 165
by Colby, 169 169 169
by Kjellin,
by Frick,
Arrangement for lessening the stray fields, 171
Suggestion by Rand Rodenhauser, 172
CHAPTER XI
THE KJELLIN FURNACE
Historical,173
The furnace, 173
Influence of the furnace contents on the power factor, 178
Comparison with an ideal furnace, 185
Issuing of licenses,192
CHAPTER XII
THE RFURNACE
Its beginning,193
The furnace, 197
Regulating transformers, auto transformers, 214
Installation costs,~~3
Issuing of licenses224
CHAPTER XIII
THE ELECTRIC SHAFT FURNACE
The Stassano electric shaft furnace, ~~5
The Keller electric shaft furnace, 226
The Helectric shaft furnace, ~~7
The test furnaces of Gr, Lindblad & Stalhane228
The Gr, Lindblad & Stalhane electric shaft furnace, 231
Influence of carbon on the energy taken up, 235
Results of operation235
Installation costs, 239
Issuing of licenses, 240
Statistics, 241
CHAPTER XIV
GENERAL REVIEW
The Chapelet arc furnace (Giffre, Allevard)242
The Keller arc furnace, 244
The Nathusius arc furnace, 245
The Gin induction furnace, 248
The Schneider-Creusot induction furnace, 248
The Gr, Lindblad & Stalhane induction and arc furnace,249
The Hiorth combination furnace and induction furnace25o
The Baily heating furnace, 253
CHAPTER XV
FINAL CONSIDERATIONS
Economical, 257
Statistics, 261
PART II
A.-MATERIALS FOR FURNACE CONSTRUCTION AND
THE COST OF OPERATION
MATERIALS FOR FURNACE CONSTRUCTION
Their general requirements, 278
"Schamotte" fire-bricks, 28o
Acid or silica bricks, 281
"Half Schamotte" fire-bricks, 281
Carbon bricks and carbon for ramming in place,
281
Basic bricks and materials for ramming in place,
282
Chrome iron ore, 282
Dolomite, 282
Dolomite plant, 282
Tar, 282
Magnesite and magnesite bricks, 283
Mortar,
283
Fluxes for the rammed part of the lining284,
Form of hearth and durability of lining, 286
THE COSTS OF OPERATION
PAGE
Influence of the kind of furnace on the quality of steel, 286
General operating costs, 287
Charge, 287
Loss in working, 288
Comparison of the heating cost in the open-hearth and electric furnace, 289
Comparison of the heating cost in the crucible and electric furnace, . 291
Statistics concerning electric steel production in Austria, 293
The amount of power used and its influence, 294
Comparison of the heating cost in the electric shaft and ordinary blast
furnace, 295
Unit price for electric power, 296
Slag-making materials, 297
Labor, 297
Costs for lining or furnace maintenance, 298
Amortization costs, 299
Cost of electrodes, 30o
Auxiliary arrangements, 300
Consumption of tools, 301
Total costs of operation of the electric shaft compared with the ordinary
blast furnace, 302
Total costs of operation of the Stassano furnace, 304
Total costs of operation of the Girod furnace, 3o6
Total costs of operation of the Hfurnace, 3o7
Increased cost through desulphurization by means of Ferro-Silicon, . 307
Total costs of operation for the Rfurnace, . . 308
B.-THE ELECTRO-METALLURGY OF IRON AND STEEL
Introduction, 31Q
THE ELECTRIC SMELTING OF IRON ORES WITH THE PRODUCTION OF
IRON AND STEEL
The smelting of ore in the Stassano furnace, 319
The smelting of ore in the Gr, Lindblad & Stalhane electric shaft furnace,
The smelting of ore in the Rinduction furnace,
Chemical balance,
Smelting results,
Criticism of ore smelting in the electrode-hearth furnace,
The smelting of ore in the electrode shaft furnace
Ore smelting tests in the special Hfurnace,
Criticism of this method of smelting
Ore smelting in the Gr, Lindblad & Stalhane furnace, . Efficiency of the furnace,
Crtiicism of the furnace
THE USE OF THE ELECTRIC FURNACE FOR MELTING FOR THE REFINING
OF PIG IRON, AND FOR THE PRODUCTION OF ORDINARY AND
SPECIAL QUALITY STEEL
PAGE
The impurities in steel: phosphorus, sulphur, silicon, copper, arsenic, carbon, oxygen, manganese, aluminum, vanadium, titanium, . . . 365
The slag-producing materials, ferro alloys, etc., used in the electric furnace: Ferro-manganese, ferro-chrome, ferro-silicon, lime, fluor-spar, iron ore, carbon, 376
The electric furnace as a melting furnace for iron and steel and iron
alloys of every kind, 378
Melting of pig iron, 379
Melting of ferro-manganese, 38o
The electric furnace as a mixer, 382
Pig-iron refining, 383
Production of special quality steel in the electric furnace, 387
From previously refined metal with low phosphorus and sulphur, 388
From previously refined metal with considerable phosphorus and
sulphur, 392
The metallurgical course of operations of an electric furnace charge,397
THE SPECIAL QUALITIES OF ELECTRIC IRON AND STEEL
Final considerations, 400
Comparison of heating costs in the open-hearth and electric furnace,401
Index, 405
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