Maximisation of energy efficiency in a six-electrode electric arc resistance furnace for high-content silicon alloys by developing innovative solutions, especially for the furnace power supply system.

Project No: POIR.01.01.01-00-0938/17

Project objective:

The project objective was to develop and implement to the industry an integrated steering algorithm for high-content silicon alloys smelting at the production line of a six-electrode electric arc resistance furnace equipped with an innovative power supply system.


Planned: PLN 55,578,238.1 Incurred: PLN 2,596,599.74


Granted: PLN 22,514,890.00
Settled: PLN 1,240,502.87


01.04.2018 – 30.12.2022 – implementation has been ceased

Project objectives:

The process of ferroalloys manufacturing is a complex technological process influenced by factors related to furnace unit energy efficiency, chemical and grain-size composition of feedstock, weighing precision along with a proper input timing and feedstock surface formation, self-baking electrodes forming, cooling of furnace structural elements, carrying the process forward by handling the furnace as well as tapping of molten metal. The key technological challenge of production in electric arc resistance furnaces is maximisation of energy efficiency of the smelting process. In order to face the challenge, the experienced Re Alloys staff, in cooperation with scientists, launched implementation of an R&D project. In the project, a modern energy supply system was devised providing electricity to operating space of furnace hearth, a key element of which is a low-loss bifilar high current circuit. Due to a significant time lag of the design stage and a massive increase of demonstration line construction costs, the project has been discontinued.
Implementation stages:

Implemented were:

  1. The first stage: an industrial research held by the Silesian University of Technology and the Research and Development Centre GLOKOR sp. z o.o., what brought the objectives and instructions for an upgraded, energy efficient technology of producing high-grade silicon alloys
    by taking advantage of the geometry of six-electrode furnace hearth (characterised by uniform distribution of energy) to the maximum.
  2. The second stage: a technical design of demonstration line elements was drawn up. The main technological challenge for designers was to match all installation elements with the innovative bifilar high current circuit and combining it all with the existing infrastructure of the furnace building. Stages planned, but not performed:
  3. The third stage: a demonstration line – a six-electrode arc-resistance furnace along with auxiliary systems, based on technical guidelines and assumptions set out in the first stage of the project and detailed designs at the second stage.
  4. The fourth stage: test runs – it was assumed that a unit indicator of energy consumption per tonne of FeSi75 produced was at the level of 8465 kWh and overall productivity at the level of 40 tonnes per day.
  5. The fifth stage: a patent application in terms of bifilar high current circuit, a technical procedure specification of FeSi production in the electric arc resistance six-electrode furnace with the use of the new, innovative, energy efficient technology.
Results of the project:

Expected results of the project:

  • increase of average active power of the furnace from 11.2 MW to 14.2 MW, that is by approx. 25%,
  • obtaining maximum, technically feasible electrical efficiency of the furnace at the level of 95% and production efficiency increase
Source of financing:
The project is co-financed with the funds of the European Fund for Regional Development within the Submeasure 1.1.1 “Industrial research and development works implemented by enterprises” within the Smart Growth Operational Programme 2014-2020.