KSK electric arc furnace.
It all started with the electric arc furnace at KSK in the 1980s. We replaced the original refractory-lined covers and upper vessels of the electric arc furnace with our water-cooled tubular constructions. And even today, much of our work revolves around electric arc furnaces, because in times of green steel production, the electric arc furnace is more in demand than ever as an electric steelmaking process.
Impressive system technology.
The key to economically successful operation lies in the system technology used. This determines how long the repair shift for your electric arc furnace will last. And when the next repair shift will be because, for example, the weld seam on the reversing cap of the third roof panel was welded without a root, contrary to the drawing. Wouldn't it be nice to know that competent fitters and welders in two small workshops in the middle of Germany would also take care of the root layers in your cover panel?
Intelligent design.
Or that our dedicated team of engineers will design your electric arc furnace top vessel in such a way that wall panels can be easily changed in a few simple steps using an overhead crane? Of course, our engineers also develop excellent technical solutions for shaft furnaces, rotary kilns, ladle furnaces, bath melting furnaces, pilot furnaces and other melting and recycling units, always in accordance with the six KSK quality criteria.
The six KSK quality criteria in the melting and recycling processes.
Clearly arranged
We design all melting units to be as clear and simple as possible so that you don't lose track of things even in critical situations and always know which valve you need to close off which cooled section. And even if it's just a routine check: Everything is much more relaxed when the hose routing is as clear as it is with this electric arc furnace.
Functional
The lid slide of your ladle furnace cover is always caught in the runner, the hinged door on the ladle furnace cover of the neighboring stand is blocked and can no longer be opened up? Of course, this can also happen to you with our water-cooled hinged slides (with hinged and sliding function) - but probably not nearly as often. The functionalities of our designs are based on 40 years of experience with electric steel processes and attention to detail - and not just on ladle furnace covers.
Innovative
You want to know what that is? No, not the immersion sleeves for the temperature sensors. The funny sockets with the screw cap underneath. Exactly! No idea what they're for? Give us a call and we'll tell you. Even though electric arc furnaces and ladle furnace covers are nothing new, we regularly develop innovative solutions in the field of electric steel processes that make your units better and your everyday life more carefree.
Perfect fit
Nothing comes off the peg for us. With us, a ladle furnace cover has an order number, not a type code. We never develop our tailor-made solutions alone, but always as a team - together with you. And if necessary, we sometimes take the time to make an extra loop in the coordination process. What counts in the end is that you don't have to bend for our technical solution, but that our bent tubes can offer you and the electrical steel process you use new technical possibilities. And even if it's just the color concept: We are happy to design according to your wishes!
Maintenance-friendly
Do you work in maintenance? Then you've come to the right place! You are the driving force behind our work. And at the same time our greatest support. We have been developing solutions for and with the maintenance sector for almost 40 years. Only those who are close to the day-to-day challenges of working with ladle furnace covers or other melting units in the electric steel process can find solutions to make this work easier. Otherwise, we would certainly never have come up with the idea of developing a self-cleaning system for ladle furnace covers.
Economical
At the end of the day, every investment should be worthwhile. Of course! When planning our systems, we therefore always keep productivity, energy efficiency, service life, material costs, spare parts availability and costs and many other aspects relating to electric arc furnaces, ladle furnace covers and the like in mind and weigh them up against each other. After all, we want to work with you in the long term!
Cooling systems and waste heat recovery
Exciting facts about the electric arc furnace
What makes the electric arc furnace so special?
Although we see ourselves as an apparatus and plant manufacturer, we are also fundamentally familiar with the electric arc furnace in terms of process engineering and metallurgy thanks to 40 years of experience in the electric steel process. We would be happy to discuss further issues beyond water cooling with you or put you in touch with a good partner from our network who, like us, is an expert in a particular technology.
The electric arc furnace itself is a unit for melting down steel scrap of various qualities. Steel can be produced from iron ore via the blast furnace and converter route. However, it makes more energy sense to melt it from steel scrap in the electric arc furnace using the electric steel process. After the electric arc furnace, the molten steel can be further processed metallurgically in other electric steel processes, such as secondary metallurgy in a ladle furnace.
Induction is also an electric steel process in which we are at home. In this electric steel process, however, our expertise is clearly limited to exhaust gas cooling. The situation is similar for other electric steel processes, such as the bath melting furnace. Here, we remain true to our motto "We do what we can and can do what we do", staying out of the metallurgy of this electric steel process as far as possible and concentrating on apparatus engineering, or in this case furnace construction.
What contribution does the electric arc furnace make to achieving EU climate targets?
The electric arc furnace is an important tool in the steel industry. It is a special furnace that is used to melt down scrap and manufacture steel products. With energy efficiency and the ability to produce clean and highly efficient steel products, the electric arc furnace makes a decisive contribution to meeting EU climate targets and reducing greenhouse gas emissions is a key element in the fight against climate change. The electric arc furnace is an important tool in achieving this goal. It enables the production of steel with minimal energy consumption, which significantly reduces greenhouse gas emissions. In addition, higher quality steel products can be produced, meaning that less energy is required to produce them, which in turn leads to a further reduction in greenhouse gas emissions.Another advantage of the electric arc furnace is that it offers a cleaner and more efficient method of producing steel. It uses a combination of electricity and gas to heat scrap, which in principle reduces the use of fossil fuels. This reduces emissions of pollutants and other harmful substances, which also contributes to reduced greenhouse gas emissions. The electric arc furnace is an important instrument for a sustainable energy supply. It uses electricity, ideally from renewable sources such as wind or solar energy, and thus enables the steel industry to produce and use steel cleanly and efficiently. This is an important contribution to a sustainable energy supply and at the same time helps to reduce greenhouse gas emissions. The electric arc furnace is a powerful tool to help the steel industry meet EU climate targets. Thanks to its energy efficiency and ability to produce clean and highly efficient steel products, the electric arc furnace makes a significant contribution to reducing greenhouse gas emissions and ensuring a sustainable energy supply. In this way, the steel industry can contribute to the implementation of the EU's climate and environmental protection targets.
What types of steel are produced in electric arc furnaces?
Special steels such as high-alloy tool steels, high-performance structural steels, high-grade structural steels, heat-resistant structural steels or low-grade steels are generally preferred for the electric arc furnace. Other special steels such as maraging steel, nitriding steel, cold work steel, etc. are also useful.
How much electricity does an electric arc furnace need?
An electric arc furnace is a key component in the steel and metal industry as it provides the ability to heat large quantities of metal to very high temperatures. The energy requirements of an electric arc furnace depend on several factors, including the size of the furnace, the type of metal to be melted, the desired melting capacity and the efficiency of the furnace. However, arc furnaces generally require a significant amount of electricity to reach the required temperatures. For a typical electric arc furnace, the power requirement can range from 500 kilowatts to several megawatts. This high power consumption makes operating an electric arc furnace a costly endeavor, especially in light of continually rising energy prices. The cost of electricity consumption can account for a significant proportion of the total cost of manufacturing, leading operators to strive to optimize energy consumption in order to reduce operating costs.To optimize electricity consumption, many arc furnace operators are turning to advanced technologies and processes that enable more efficient use of energy. These include, for example, the implementation of heat recovery systems that allow the heat emitted from the furnace to be used to generate electricity or heat buildings. In addition, modern electric arc furnaces are often equipped with computerized systems that make it possible to precisely monitor and control energy consumption. This can help to optimize electricity consumption and improve the energy efficiency of the furnace, and another approach to reducing electricity consumption is to switch to alternative energy sources that are more environmentally friendly and cost-effective. More and more electric arc furnace operators are investing in renewable energy such as solar or wind power to reduce their need for conventionally generated electricity.
What happens in the electric arc furnace?
Metals and other electrically conductive materials are melted in an electric arc furnace. The arc melting process is based on an electric arc being generated between the electrodes of the furnace. This arc heats the material in the furnace to very high temperatures, causing it to melt. The electric arc furnace is often used in the metallurgical industry to produce steel and other alloys. The melting process in the electric arc furnace enables precise control of the melting temperature and composition of the alloy. In addition, specific properties of the end product can be influenced by adding different alloying metals. The arc melting process is also more energy efficient compared to other melting processes, as it converts electrical energy directly into heat without the need to use fossil fuels. By using recycled materials, the electric arc furnace can also help to conserve resources. Once the material has melted in the arc furnace, it is poured into special molds to obtain the desired final shape. The entire process in the electric arc furnace takes place under controlled conditions to ensure consistent quality of the end product. In addition, pollutants and impurities can also be removed from the material in the electric arc furnace, resulting in a higher purity of the end product. The recycling of metallic waste is also an important application of the electric arc furnace, as the high temperatures in the furnace help to remove most impurities and make the recycled material usable again for the production of new products. Overall, the electric arc furnace plays an important role in metallurgy and the recycling of metallic materials, as it enables efficient melting processes and can help to conserve resources and reduce environmental impact.
What is the advantage of the electric steel process?
The electric steel process offers numerous advantages that make it an attractive option for steel production. One of the most important advantages is the ability to produce high-quality steel with reduced CO2 emissions. Compared to conventional steelmaking processes, such as the blast furnace process, the electric steelmaking process produces significantly fewer emissions, which helps to reduce the negative impact on the environment. In addition, the electric steel process allows for more flexible manufacturing, as it can react more quickly to changes in demand. This leads to improved adaptability and efficiency in steel production, which ultimately results in cost savings. Another advantage of the electric steel process is the ability to produce a variety of steel grades, including high-alloy steel and special steels. This makes the process versatile and allows manufacturers to cater to the specific requirements of their customers. In addition, the electric steel process also offers advantages in terms of working conditions. Compared to other processes, there is less noise and air pollution, resulting in an improved working environment for employees. Overall, the electric steelmaking process offers an efficient, environmentally friendly and versatile method of producing steel, which is an attractive option for steel manufacturers. It is important that the industry recognizes these benefits and increasingly considers the electric steelmaking process to reduce environmental impact and improve efficiency and flexibility in steel production. By opting for more sustainable and efficient methods of steel production, we can help protect our environment and ensure the long-term competitiveness of the steel industry.
What happens in a steel mill?
Many important processes that are required to produce steel take place in a steelworks. First of all, raw materials such as iron, coal and limestone are processed in the blast furnaces to melt the iron and remove impurities. This process requires a very high temperature, often over 1500 degrees Celsius. Once the iron has melted, it is poured into various molds to give it the desired shape. The steel is then further processed by rolling, forging or other methods to improve its strength, hardness and other properties. Throughout the process, various machines and equipment play an important role in making manufacturing efficient and safe. In addition, qualified employees and engineers are essential to ensure the smooth running of manufacturing and to ensure the quality of the end product. Finally, compliance with strict environmental regulations is also a key part of the steel mill process to ensure that the impact on the environment is kept to a minimum.Apart from the mechanical and technical aspects, employee safety also plays a crucial role in a steel mill. Due to the high temperatures, heavy machinery and chemical substances, there is always a certain risk of injury. It is therefore essential that strict safety protocols are followed and employees are regularly trained to prevent accidents. Regular inspections and maintenance are also carried out on the equipment to ensure that it is operating safely and efficiently.In addition to these technical and safety aspects, the economic importance of a steel mill also plays an important role. The steel industry contributes significantly to a country's economy by creating jobs, supporting the growth of other industries and enabling important infrastructure projects. In many countries, steel production is an essential part of the economy and plays a key role in industrial development.
