Introduction	6
	Contents	8
	1 EAF in Global Steel Production	11
	Abstract	11
	1.1 Production of Steel from Scrap Is EAF’s Mission	11
	1.2 Melting a Scrap as a Key Process of the Heat	13
	1.3 Unjustified High Electrical Energy Consumption	13
	1.4 Problems of Ultra-High Power (UHP) EAFs with Regard to Energy	14
	1.5 High Productivity or Low Costs?	15
	References	16
	2 Analysis of Technologies and Designs of the EAF as an Aggregate for Heating and Melting of Scrap	17
	Abstract	17
	2.1 Melting a Scrap by Electric Arcs. Function of Hot Heel	17
	2.1.1 Single Scrap Charging	18
	2.1.2 Telescoping Shell	19
	2.2 Heating a Scrap by Burners in the Furnace Freeboard	19
	2.2.1 Specifics of Furnace Scrap Hampering Its Heating	19
	2.2.2 Stationary Burners and Jet Modules	20
	2.2.3 Rotary Burners with Changing the Flame Direction	24
	2.2.3.1 Slag Door and Oriel Rotary Burners	25
	2.2.3.2 Roof Rotary Burners	27
	2.2.4 Two-Stage Scrap Melting. Industrial Testing of the Process	29
	2.2.4.1 Two-Stage Process in 100-t and 200-t EAFs	30
	2.2.4.2 Two-Stage Process in Plasma Furnaces	31
	2.2.5 Twin-Shell EAFs	32
	2.2.5.1 Twin-Shell Shaft Furnaces	34
	2.3 EAF with Preheating a Scrap by Off-Gases and Melting of Preheated Scrap in Liquid Metal	35
	2.3.1 Conveyor Furnaces of Consteel-Type	35
	2.3.2 Shaft Furnaces with Fingers Retaining Scrap	39
	2.3.2.1 Calculation	41
	2.3.2.2 EAF Quantum	42
	2.3.2.3 EAF SHARC	44
	2.3.3 Shaft Furnaces with Pushers of the COSS-Type	45
	2.3.3.1 Shaft Furnaces of ECOARC-Type	46
	2.4 Factors Hindering Wide Spread of Shaft Furnaces	47
	2.4.1 Calculation of the Maximum Values of the Power of the Heat Flow of Off-Gases and Temperature of Scrap Heating by These Gases in the Shaft	48
	References	49
	3 Experimental Data on Melting a Scrap in Liquid Metal Required for Calculation of This Process	50
	Abstract	50
	3.1 Features of Scrap Melting Process	50
	3.2 Studies of the Melting Process by the Method of Immersion of Samples in a Liquid Metal. Analysis of the Results	52
	3.2.1 Melting of Single Samples of Scrap with a Solidified Layer and Without Solidifying	52
	3.2.2 Co-melting of Multiple Samples	57
	3.2.3 Porosity of Charging Zone and Bulk Density of Scrap	59
	References	59
	4 Calculations of Scrap Melting Process in Liquid Metal	60
	Abstract	60
	4.1 Scrap Melting Time	60
	4.2 Adaptation of Experimental Data Obtained by the Method of Melting Samples to Real Conditions of Scrap Melting	61
	4.2.1 Equivalent Scrap	61
	4.2.2 Correction Coefficients KP, KL, Kts and K?	62
	4.2.2.1 Coefficient KP, Adjustment of Porosity P in the Charging Zone	62
	4.2.2.2 Coefficient KL, Adjustment of Temperature of Metal tL	62
	4.2.2.3 Coefficient Kts, Adjustment of Scrap Preheating Temperature tS	62
	4.2.2.4 Coefficient K?, Adjustment of Metal Stirring Intensity	63
	4.3 Calculation Method of Scrap Melting Time in Liquid Metal	64
	4.3.1 General Characteristic of the Method	64
	4.3.2 Examples of Calculations of Scrap Melting Time	64
	4.3.2.1 Conveyor Furnace Consteel	64
	4.3.2.2 Shaft Furnace Quantum	65
	4.3.2.3 Influence of Scrap Quality	66
	4.3.3 Specific Scrap Melting Rate	67
	References	68
	5 Increasing Scrap Melting Rate in Liquid Metal by Means of Oxygen Bath Blowing	69
	Abstract	69
	5.1 Preliminaries	69
	5.2 Tuyeres with Evaporation Cooling Embedded in the Lining	71
	5.3 Roof Water-Cooled Tuyeres for Bath Blowing at Slag-Metal Interface	74
	5.3.1 Thermal Operation of Tuyeres: Heat Flows, Temperatures	74
	5.3.1.1 Operation of Tuyeres with Local Water Boiling	77
	5.3.1.2 Jet Cooling	79
	5.3.2 Roof Tuyere with Jet Cooling	81
	5.3.2.1 Controlling the Optimal Position of Roof Tuyere Relatively to Slag-Metal Interface	84
	References	86
	6 High-Temperature Heating a Scrap in a Furnace Shaft	87
	Abstract	87
	6.1 Preliminary Considerations and Evaluation of Some Parameters	88
	6.1.1 Calculation of Scrap Heating Time with off-Gases in the Quantum Shaft	89
	6.2 Scrap Preheating System by High-Power Recirculation Burner Devices	90
	Reference	93
	7 Fuel Arc Furnace—FAF	94
	Abstract	94
	7.1 Concept of the Fuel Arc Furnace	94
	7.1.1 Selection of the Quantum Constructive Scheme as a Base for FAF	95
	7.1.2 Calculations of Main Parameters and Performances of the FAF	96
	7.1.2.1 Data on Parameters and Operating Conditions of the furnace Required for Calculations	96
	7.1.2.2 Calculation of Scrap Preheating Time	97
	7.1.2.3 Required Transformer Power and Electrical Energy Consumption	97
	7.1.2.4 Power of Burner Devices and Natural Gas Flow Rate	98
	7.1.2.5 Tap-to-Tap Times and Hourly Productivity	98
	7.2 Advantages of Fuel Arc Furnaces FAF of Quantum-Type	98
	Reference	99
	Index	100