EAF Shell

EAF (Electric Arc Furnace) Shell

Furnace Structure

        The EAF adopts a split shell design featuring water-cooled sidewalls, a water-cooled roof, and an eccentric bottom tapping (EBT) system.

        The furnace body consists of an upper shell, lower shell, furnace door, EBT mechanism, and water-cooled sidewall panels. The upper shell is fabricated with a seamless steel tube frame structure, which also serves as the cooling water distribution and return manifold.

        The lower shell incorporates the EBT system and is fabricated from a cylindrical shell with a dished bottom.

During tapping, a hot heel of approximately 20–30% is retained. Under normal operating conditions, complete tapping can be achieved with a furnace tilting angle of 12°–15°. If bottom wear results in the formation of a depression during the later stage of campaign life, the tilting angle can be increased up to 20° to facilitate complete steel removal.

Water-Cooled Sidewall System

        The water-cooled sidewall panels adopt a dense-tube design and are arranged in multiple independent sections around the furnace shell.

        Several panels are provided with openings for wall-mounted burners. Each cooling circuit is equipped with individual inlet and outlet isolation valves. Outlet water temperature is continuously monitored to ensure effective cooling performance and operational safety.

        The main cooling water system is equipped with pressure, flow, and temperature monitoring instruments. Parameters including inlet pressure, inlet flow rate, inlet temperature, and outlet temperature are continuously monitored and displayed in the control system.

Maintenance & Operation

        The upper and lower shells are connected by hinge pins for easy dismantling and maintenance. Heavy-duty lifting lugs are provided on the furnace shell to allow the complete shell assembly to be lifted and removed when required.

        The furnace door is hydraulically operated and water-cooled. Adequate space is provided for the operation of the water-cooled carbon-oxygen lance.

        The eccentric bottom tapping (EBT) mechanism is mounted on the furnace body and hydraulically operated. The system ensures safe, reliable, and efficient tapping. Manual operation is available as an emergency backup.

Quality Assurance

        To ensure long service life and reliable operation under severe thermal cycling conditions, all water-cooled components are manufactured under strict quality control procedures:

       • CNC cutting and bevel preparation to ensure welding accuracy and eliminate inaccessible welding areas.

       • TIG root welding followed by MIG/MAG filling and capping to ensure weld integrity and full penetration.

       • Stress-relief heat treatment for critical welded structures after fabrication.

       • Non-destructive testing (UT/RT) performed on critical weld seams.

      • Hydrostatic pressure testing and leakage inspection conducted on every unit before delivery.

       • Complete surface sandblasting followed by a high-temperature-resistant anti-corrosion coating system.

Key Features

       • Standardized heavy-duty welding procedures applied to all water-cooled components.

       • Improved resistance to thermal fatigue, deformation, and cracking through stress-relief treatment.

       • Internal weld defects are identified and eliminated through non-destructive examination.

       • 100% hydrostatic testing before shipment to ensure leak-free operation.

       • High-performance anti-corrosion protection for extended service life in high-temperature and corrosive environments.

       • Designed for reliable operation and reduced maintenance requirements in demanding metallurgical applications.

Manufacturing Standard

        Manufactured to heavy industrial equipment standards rather than conventional sheet-metal fabrication practices, ensuring superior reliability, durability, and long-term performance in steelmaking and ferroalloy production environments.