Akronim: SINARC
Project No.: SINARC
Project objective:
Development and testing under industrial conditions of a technology for producing ferrosilicon alloys (Si ≥75% by mass) using a plasma arc in a submerged arc furnace. This solution will enable process intensification, improve thermal conditions in the reaction zones and increase the rate of chemical reactions, resulting in lower specific energy consumption, increased furnace productivity and a reduced carbon footprint of the product.
The project is being carried out by a consortium comprising an industrial partner (Re Alloys S.A. – Consortium Leader) and a research organisation (the Institute of Plasma Physics and Laser Microfusion).
PROJECT
VALUE:
PLN 39,733,057.02
TOTAL ELIGIBLE
PROJECT COSTS:
PLN 27,665,923.31
EUROPEAN
FUNDS CONTRIBUTION:
PLN 13,187,338.72
PROJECT IMPLEMENTATION
PERIOD:
from 01/11/2026 to 30/11/2029
The project aims to develop and test an innovative technology for producing FeSi75 ferrosilicon, designed to improve energy efficiency and increase the productivity of the manufacturing process in submerged arc furnaces.
The innovative aspect of the solution involves introducing a stream of plasma-forming gases directly into the zones beneath the furnace electrodes to stabilise the electric arc, improve heat energy distribution and intensify metallurgical reactions. The technology is intended to enable more efficient use of electricity while reducing the consumption of operating materials and CO₂ emissions per tonne of ferrosilicon produced.
The project includes comprehensive research and development activities, including the development of mathematical and process models, investigations into the properties of electric arcs in an atmosphere of plasma-forming gases, the development of plasma diagnostic methods, and laboratory experiments and industrial-scale technological trials.
A key element of the project will be the validation of the developed technology under actual ferrosilicon production conditions using a 20 MVA submerged arc furnace.
Implementation stages:
R&D Module
Task 1. Development of an integrated process model for the production of high-silicon alloys using a plasma arc by introducing a stream of plasma-forming gases into the zone beneath the electrodes of a submerged arc furnace.
Task 2. Development of a mathematical model of electric arc behaviour in the zone beneath the electrodes of a submerged arc furnace used for FeSi75 ferrosilicon production, taking into account the temperature and composition of the gaseous atmosphere.
Task 3. Development of a method for the precise introduction of selected plasma-forming gases into the zone beneath the electrodes of a submerged arc furnace to control the electric arc atmosphere during the smelting of high-silicon alloys (FeSi75).
Task 4. Design and construction of a laboratory test rig to investigate the influence of gas mixture composition on electric arc characteristics.
Task 5. Development of a measurement system and performance of spectral measurements on the test rig to estimate the temperature and chemical composition of the plasma.
Task 6. Conducting laboratory trials of ferrosilicon production with a minimum silicon content of 75% by mass in a submerged arc furnace using a plasma arc.
Task 7. Spectroscopic measurements and model validation in a laboratory submerged arc furnace.
Task 8. Construction of a comprehensive system for introducing plasma-forming gases into the zone beneath the electrodes of a 20 MVA submerged arc furnace designed for the production of high-silicon alloys.
Task 9. Development of a technology for producing high-silicon alloys using a plasma arc by introducing a stream of industrial-grade plasma-forming gases into the zone beneath the electrodes of a submerged arc furnace.
Task 10. Connection of measurement equipment and performance of measurements during industrial trials in a 20 MVA submerged arc furnace used for ferrosilicon smelting.
Project Results and Beneficiaries:
Zastosowanie innowacyjnego rozwiązania pozwoli na zwiększenie rezystancji łuku, zwiększenie objętości stref reakcyjnych oraz poprawę warunków cieplnych prowadzących do intensyfikacji reakcji chemicznych. Rezultatem będzie obniżenie jednostkowego zużycia energii elektrycznej (z poziomu 8,353 MWh/t do ok. 8,150 MWh/t), wzrost wydajności dobowej jednostki piecowej 20 MVA (z 46,65 t/d do 48,16 t/d), obniżenie wskaźnika zużycia masy elektrodowej z 40 kg/t na 32 kg/t, poprawa stabilności parametrów elektrycznych łuku oraz redukcja emisji CO₂ przypadającej na tonę stopu (z ok. 3 510 do ok. 3 377 kg CO₂/t FeSi75).
Efektem końcowym będzie opracowana, sprawdzona w warunkach przemysłowych i gotowa do wdrożenia technologia, którą będzie można zastosować w kolejnych piecach zakładu, co zwiększy konkurencyjność i efektywność produkcji Re Alloys.
Pośrednimi odbiorcami będą przedsiębiorstwa przemysłu stalowego i odlewniczego, wykorzystujące żelazokrzem FeSi75 w procesach metalurgicznych, w szczególności odbiorcy zainteresowani surowcami wytwarzanymi w sposób bardziej energooszczędny i o niższym śladzie węglowym.
Rezultaty projektu będą również istotne dla środowiska naukowego i badawczego, przyczyniając się do rozwoju wiedzy w zakresie fizyki plazmy oraz technologii procesów metalurgicznych.
Source of financing:
Project co-financed by EU funds within the European Funds for Modern Economy Programme, measure FENG.01.01 – Strand SMART.
#EuropeanFunds #EUFunds
