R&D FACTS Electric Arc Furnace Research Facility - National ...

Electric Arc Furnace Research Facility
The electric arc furnace (EAF) research facility located at the NETL Albany site,
Oregon, has a 50 year history of pyrometallurgical research into primary smelting,
steelmaking, waste treatment, and recycling. The EAF research facility includes a
unique set of furnaces sized from bench- to pilot-scale.
The furnaces include:
• 50 kW, single-phase AC,
tilting-shell
• 300 kW, single-phase AC,
tilting-shell EAF
• 0.8 MW, three-phase AC,
static-shell EAF
Case Histories Melting (Vitrification)
• Simulated low-level radioactive wastes
• Cr- and Pb-contaminated soils
• Dredging spoils
• Coal boiler bottom ash
• Mineral wool
Smelting
• Primary Fe, Cr, Ni & Ti ores
• Zn smelter wastes
• Aluminum potliner
• PGM-bearing catalyst wastes
• Silicon smelting
• Iron ore sands
Slag tap from the 300 kW EAF
Top view of silicon smelting furnace
Albany, OR • Fairbanks, AK • Morgantown, WV • Pittsburgh, PA • Sugar Land, TX
Website: www.netl.doe.gov
Customer Service: 1-800-553-7681
R&D FACTS
Process Development Division
CONTACT
Cathy Summers
Director, Process Development Division
National Energy Technology Laboratory
1450 Queen Ave., SW
Albany, OR 97321-2198
541-967-5844
cathy.summers@netl.doe.gov

Iron/Steelmaking
• Cast iron scrap
• Steel scrap
• Steel casting
consolidation
The 50 kW EAF is a
versatile unit, with
interchangeable shells
for acid/basic/carbon
practice, and is utilized
to develop a smelting/
melting practice for
virtually all materials
to be processed in the
larger scale EAF. The
150 kW Si-smelting
furnace consists of a
Pouring iron pigs from ladle
single top electrode with
a carbon (graphite) hearth and is scaled for a production rate
of roughly 5 kg Si per hour. In the past year, direct smelting
of iron ore sands has been conducted in the 300 kW, singlephase
AC EAF. Roughly 2 tons of briquetted ore was smelted
in 6 heats conducted over 3 days, producing over 1,100 lb of
pig iron at a reduction efficiency of nearly 90 percent.
Schematic of 0.8 MW EAF system
The 0.8 MW EAF is a dual-purpose smelter/melter, and has
been used for several pilot-scale demonstrations in both
modes of operation. The furnace is sealed and can be kept
at a slight negative pressure for environment control. The
system includes continuous feeding by metered screw
conveyors, and a dedicated air pollution control system,
including a close-coupled thermal oxidizer, with particulate
and acid gas control.
Emissions monitoring can be conducted by gas chromatograph
and individual gas analyzers on both of the pilotscale
EAF. Gases analyzed include C 2 H 6 , CH 4 , CO, CO 2 , H 2 , O 2 ,
NO x , and SO 2 .
Much of the work conducted at the NETL EAF research
facility has been funded through Cooperative Research
and Development Agreements (CRADA) and Contributed
Funds-In Agreements. These agreements have included
both industry and federal agency partners. The scale and
variety of furnaces available make the facility a unique
research and development tool for the U.S. Department
of Energy.
Metal tap and 0.8 MW EAF system
R&D112, March 2012