Factors Influencing Submerged Arc Furnace Pricing
The price of a Submerged Arc Furnace (SAF) is determined by its specifications, capacity, design features, and the scope of supply. This overview is based on a common configuration: a semi-enclosed, fixed-body furnace with a low fume hood.
1.1 Furnace Body
The furnace body is a critical cost component, comprising the steel shell, refractory lining, and foundation.
Shell & Structure: Constructed from 14–18 mm thick steel plate, reinforced with external ribs for structural integrity. The base utilizes 18–20 mm plate, supported by heavy I-beams (25–30). The shell includes 1–2 tap-holes and is naturally ventilated for bottom cooling.
Refractory Lining: A composite lining using high-alumina bricks and self-baking carbon bricks. Typical thicknesses are 460–690 mm for walls and 800–1200 mm for the hearth bottom. An external 20 mm ceramic fiberboard provides insulation. The tap-hole and spout area uses silicon carbide-corundum bricks, often with a water-cooled spout structure. Optional water-cooled furnace doors affect the final price.
1.2 Low Fume Hood
Two primary designs influence cost:
Full Water-Cooled Structure: Comprises a water-cooled frame (16–20 channel steel), cover plates, walls, and coamings. Critical areas around electrodes use non-magnetic stainless steel. This design offers excellent durability and maintenance access.
Composite Structure: Features a water-cooled steel skeleton with sidewalls built from refractory bricks. It includes maintenance doors and connects to vertical cooling ducts leading to the gas cleaning system.
The choice between these impacts both initial investment and long-term maintenance costs.
1.3 Short Network & Busbar System
The design of the low-voltage, high-current busbar system (short network) is crucial for electrical efficiency and cost.
Layout & Components: Includes water-cooled compensators, copper tubes, flexible cables, and contact clamps (copper tiles). Layouts (regular or inverted triangle) aim to minimize length and impedance to maximize power transfer.
Innovative Design: Utilizing thick-walled, reverse-parallel connected water-cooled copper tubes creates a two-wire system that cancels inductive reactance. A closed-loop cooling circuit for the entire short network (from busbar to copper tile) minimizes resistive losses, improves efficiency, and reduces copper mass, offering a more economical solution.
1.4 Electrode System
A sophisticated system based on international technology (e.g., Demag, Pyromet).
Components: Includes the electrode column, holding cylinder, pressure ring, copper tiles (6–8 per electrode), water-cooled sleeve, and lifting/pressing mechanisms.
Key Features: Hydraulic electrode lifting allows precise control. An automatic slip system uses upper/lower pneumatic (or hydraulic) brakes coordinated with a release cylinder to safely lower the self-baking electrode. The pressure ring ensures uniform clamping force and optimal electrical contact from all copper tiles.
1.5 Cooling Water System
A dedicated system cools all high-temperature components: short network, pressure rings, furnace shell, and fume hood. It comprises headers, piping, valves, gauges, and quick-disconnect couplings for maintenance. A dedicated drain for the short network allows for rapid dewatering. Water quality requirements are strict: softened water with inlet ≤30°C and outlet ≤50°C.
2.1 Furnace Transformer
A high-efficiency, shell-type transformer with on-load tap changing (OLTC) is standard. Key specifications affecting price include:
High-voltage side: 35–110 kV.
Low-voltage side: 5–27 voltage steps (adjusted for furnace capacity and product).
Features: Oil-water cooler, impedance voltage of 4–6%, overload capacity >25%, and side-outlet bushing connections.
2.2 High & Low Voltage Supply
High-Voltage System: Includes disconnect switches, vacuum circuit breakers, and protection for the 35/110 kV feed to the furnace transformer. Optional harmonic filters and primary-side power factor compensation are available.
Low-Voltage System: A dedicated auxiliary transformer powers all plant utilities (pumps, controls, PLCs, hydraulic stations), with optional secondary-side compensation.
Pricing varies significantly with the scope of auxiliary systems supplied.
Feed System: Options range from belt conveyors to bucket elevators with distribution cars and silos.
Tap-Handling: Includes ladles, ladle transfer cars, or gantry cranes.
Casting: Ingot molds or other casting equipment.
Furnace Tools: Tapping drills, clay guns, and manual/mechanized feeders.
Environmental Control: Dedicated fume extraction and baghouse dust collection systems.
Power Quality: High and low-voltage compensation systems (optional).
Our company provides end-to-end solutions, which influence overall project value beyond mere equipment pricing. Our services include:
Consulting, engineering design, and equipment system integration.
Full EPC (Engineering, Procurement, Construction) turnkey project execution.
Supply of materials and equipment.
Process management, training, and operational support.
Our expertise is backed by a team of over 60 experts and 300+ engineers specializing in ferroalloys and green steelmaking, with more than 20 years of experience. We hold relevant national design and construction qualifications and are ISO9001 certified for quality management.
Conclusion:
The final price for a Submerged Arc Furnace is not a single figure but a reflection of a customized engineering package. It is determined by the furnace capacity, selected technological configuration (e.g., hood type, short network design), the extent of automation, the scope of auxiliary systems, and the level of engineering services required.
We are a professional electric furnace manufacturer. For further inquiries, or if you require submerged arc furnaces, electric arc furnaces, ladle refining furnaces, or other melting equipment, please do not hesitate to contact us at susie@aeaxa.com
