Submerged arc furnace (ferroalloy)

Primary products
Ferroalloys

Our international experts are passionate about electric smelters and submerged-arc furnaces for the production of ferroalloys, silicon, non-ferrous metals, and minerals. This is a field where SMS group in Düsseldorf and Metix in Johannesburg pool their know-how for your benefit. Our team in Düsseldorf handles all SAF-related projects for electric smelters and submerged-arc furnaces worldwide, except in southern Africa. Metix is not only responsible for all submerged-arc furnace and electric smelter projects in the southern African region, but also supplies feed material pre-heating systems as well as pellet and sinter plants. Paul Wurth provides support with refractory design and tapping/stoking equipment. We join forces with you to work together as a team, always finding the best possible solution. Our team is available at all times to stand by your side and help you get the results you want.

Application

Recent years have been exciting for SMS group. That's because of the many fascinating and challenging furnace projects we implemented or are currently working on. Included here are the world's largest-ever FeNi furnace, the first large-scale FeCr production line based on DC technology, silicon plants, FeMn plants, and special alloy furnaces such as FeNb furnaces. Read on for our latest references in the field of ferroalloys, nonferrous metals, special applications, and hot metal. These references provide the basis for successful smelter operation.

FeNi image

FeNi

Ferronickel is mainly produced in submerged-arc furnaces by reducing lateritic nickel ores. The process aims to transfer most of the nickel into the metal phase. It starts with pre-heated and pre-reduced ores which are hot charged as calcine ...

FaCr image

FeCr

What distinguishes high-carbon ferrochrome is the carbon content of 4-8%. It's usually used in AOD con- verters to produce alloyed steel grades. Due to environ- mental restrictions, ferrochrome is commonly produced in closed, stationary furnaces. ...

FeMn / SiMn image

FeMn / SiMn

Ferro-manganese is usually available on the market in the form of high-carbon (6-8%C), medium-carbon (1 - 4%C), or low-carbon (< 0.4%C) products. There are also alloys with high Si contents (15 - 20%) known as silico- manganese. High-carbon ferro-manganese ...


Technology

Methods and technology

Crucial for our excellent design are our experienced experts, plus a strong R+D department, and advanced engineering tools. All this makes it possible to calculate complex structural furnace parts and intensive thermal areas. These are capabilities even more important for designing large-capacity furnaces. Moreover, FEM calculation is an extra option for cutting electrical losses with alternating magnetic fields.

Our customers have told us again and again that our designs result in reliable and efficient plants. That's because our engineering also ensures long equipment and component service lives. Some SMS group furnaces have been in operation for more than 40 years - and are still running smoothly.

Methods and technology image

Portfolio / Competencies


Overview products portfolio SAF & electric smelter

We can supply complete processing lines - starting with raw material charging and continuing right through to dispatch of the finished products for the metals and chemical industry.

Basic systems image
  • AC based or DC-based
  • Open design, semi-closed or closed design

Furnace shell types

  • Flat/dished bottom
  • Cylindrical/conical/rectangular 
  • Stationary/rotating
  • Changeable/tiltable
Electrode systems image
  • Pre-baked/graphite or self baking 
  • Composite system
  • Hollow electrode system

Furnace shell types

  • Water cooled roofs (steel of copper)
  • Brick roof/cast roof (optional air cooling) 
  • Flat/arched shape
Charging systems image
  • Hot/cold charging
  • Hollow electrode charging 
  • Liquid charging (launder)

Additional competencies

Metallurgical competencies image

Each process requires extensive and in-depth process know-how. You benefit from the expertise of our metallurgical department because it provides a solid basis for efficient design as well as safe and reliable operation of your applications. We also team up with many plant operators and renowned institutes worldwide. What has emerged over decades of development in this field is a metallurgical model founded on practical and scientific data.

Our in-house software for complex metallurgical evaluation combined with our experienced employees are your guarantee for reliable and achievable figures. Working hand in hand with the metallurgical department means our experts define the right processes and furnace dimensions for you. This results in perfect solutions for your specific metallurgical requirements. Plus: intelligent dimensioning gives you higher yield and keeps your consumption low.

Turnkey competencies image

The SMS group turnkey department is noted for its expertise in planning and supplying complete plants of any size for ferroalloys, nonferrous metals, and other products worldwide. As leading partners in consortiums or as plant planning specialists, we offer you comprehensive know-how
and a wide spectrum of services. Our full technical service ranges from the planning and project phase to the handover of the turnkey plant. We also provide engineering for individual plant sections that are subsequently combined with other units to build a complete plant. Acting as an EPC/EPCM contractor, SMS group has implemented many projects based on these business models:

  • Business model 1: Core equipment delivery (e.g. Barro Alto/Brazil)
  • Business model 2: Turnkey equipment delivery (e.g. Silicium Kazakhstan)
  • Business model 3: Business model 2 + local engineering by SMS group, procurement and construction by customer with SMS group assistance (e.g. Vale/Brazil, Kazchrome/Kazakhstan)
  • Business model 4: Business model 3 + local civil engineering and construction engineering by SMS group (e.g. PCC Bakki/Iceland)

There is no better indication of the SMS group Johannesburg office's competence in EPC services than the impressive track record of Metix in installing plants with full budget and time responsibility. Metix enjoys an excellent reputation - particularly in FeCr sinter plants (based on Outotec design and technology) and electric smelters. The Sakura project in Malaysia, where SMS group is supplying a complete FeMn-plant, is managed on a full EPC contract basis.

Studies image

Besides supplying engineering, equipment, and plant, we also provide these services and engineering:

  • Operating cost optimization
  • Environmental impact studies
  • De-bottlenecking, plant logistics, process modeling
  • Technical feasibility studies
  • Product optimization programs and product change/expansion plans

Service

Upgrades and modernizations

Over the past 35 years, SMS group has modified more than 80 submerged-arc furnaces. Revamping plants is challenging because of the nature of brownfield design. It requires the lowest possible downtime during revamping as well as adapting the existing plant environment. Our smart solutions are designed to achieve higher production levels while retaining the approximate dimensions of both the furnace and the plant. We do this by revamping the electrode columns, side wall cooling system, and thyristor control system, and enlarging the transformer capacity. It’s also possible to boost production with intelligent logistical improvements and charging patterns. The potential capacity expansion from a newly-developed copper cooling system was demonstrated by a rectangular submerged-arc furnace in New Caledonia. Here, we doubled the capacity of each furnace without altering the dimensions.  

Services and spare parts

Maintaining plants at this high level of operation demands sophisticated and efficient spare parts and components management as well as servicing. That’s where our team of specialists comes in – ready to offer you customer support in all spare parts-related issues. Equally important is our commitment to improving the performance of your existing plant units. Total quality management always forms an essential part of our services. Therefore we repair and manufacture wear parts in our workshops worldwide, or source them from our qualified suppliers. Our specialists also assist locally when repair work is necessary. Simply contact our team with any inquiries about effective spare parts management. 

service image

Selected References

ReferencesSince 2000

SMS group, a strong partner

SMS group supplies a wide product portfolio to end users who process ferroalloys, PGM, NF metals, iron, and steel. Over the last 100 years, we have developed many processes to produce more than 60 different kinds of metals and slags (collecting in excess of 750 references) Internationally, SMS group ranks among the strongest players in the field of all smelter components, equipment, and plant solutions. Today we are the global leader in metallurgical plant and machines, not least because we integrated top names such as Demag, Krupp, Krupp Technologie, Schloemann, Concast, MAN-GHH, Paul Wurth, and Metix.

SMS group constantly develops applications for all kinds of customers. They are located throughout the world, predominantly in countries with large raw material reserves and/or low energy costs.

SMS group, a strong partner image

Electrical and automation systems


Future-proof complete solutions from one source

  • Integrated solutions consisting of mechanics, electrics, and automation
  • The benefits of long-term experience with X-Pact® world-leading automation
  • Energy distribution and drive systems
  • The only genuine future-proof automation system
  • Control stations designed around the operator
  • Innovative HMI system for production-centered operation
  • Plug & Work integration test, process and production simulation, near-reality 3D visualization
  • All-inclusive modernization
  • International setup
Electrics and automation systems image

Holistic, efficient, and future-proof

Products and solutions for submerged arc furnaces

solutions
SAF HD Monitoring
Water leakage detection system
SAF reporting system
Thyristor control
SAF electrode regulator
Your professional partner for submerged-arc furnaces

Our specialists in electrics, automation, technology, and mechanics work hand in hand to ensure your systems function smoothly. That’s how we create intelligent, market-centered solutions that boost your production. Only optimized automation technology enables you to produce a wide range of ferroalloys and nonferrous metals in modern SAF plants. This saves you both money and resources in the form of raw materials and energy.

Downloads

Future-proof complete solutions from one source - Electrics and Automation
Download
SAF Bulletin
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Energy-efficient gas cleaning
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Ahead of Times with Plug & Work
Download
SAF HD Monitoring
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Ecoplants: Acting Economically – Growing Sustainably
Download
Integrated Process Control in the Steelworks
Download
SAF Reporting System
Download
X-Pact Vision Operation and visualization
Download
Production Planning and Scheduling
Download

Contact

SMSgroup Fröhling,Dr. Christian

Dr. Christian Fröhling

SMS group GmbH
Technical Sales SAF/Gas Cleaning Syst./Energy/Environment
Eduard-Schloemann-Straße 4
40237 Düsseldorf
Germany

Phone : +49 211 881 5288
Fax : +49 211 881 775288

SMSgroup Degel,Dr. Rolf

Dr. Rolf Degel

SMS group GmbH
Vice President Special Metallurgical Plants
Eduard-Schloemann-Straße 4
40237 Düsseldorf
Germany

Phone : +49 211 881 6372
Fax : +49 211 881 776372

SMSgroup Köneke, Martin

Martin Köneke

SMS group GmbH
Submerged arc furnaces
Eduard-Schloemann-Straße 4
40237 Düsseldorf
Germany

Phone : +49 211 881 6584
Fax : +49 211 881 776584

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