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DC furnace for vanadium iron slag treatment (mostly DC arc furnace / DC submerged arc furnace) is the core equipment for vanadium-iron alloy smelting, vanadium-titanium magnetite smelting and resource utilization of vanadium iron slag. Using DC electric arc as the heat source, it realizes deep reduction of vanadium iron slag, efficient separation of slag and iron, and high-efficiency recovery of valuable metals (vanadium, iron) at a high temperature of 1500–1700℃, which is the mainstream technical route for resource utilization of vanadium slag at present.
I. Core Principle
Heat Source Mechanism: Adopting DC arc discharge, a stable, directional and high-energy-density plasma arc column is formed between the graphite electrode (cathode) and the furnace bottom anode, with a temperature reaching 1500–1700℃, featuring concentrated energy and high thermal efficiency.
Treatment Process:
Vanadium iron slag is completely melted at high temperature, with reductant (carbonaceous material) and flux (lime) added to achieve deep reduction of vanadium and iron oxides.
The reduced vanadium-iron alloy sinks to the furnace bottom due to high density, while vanadium-rich slag / titanium slag floats on the upper layer, realizing efficient separation of slag and iron.
The recovery rate of valuable metals (vanadium, iron) is high, and the tailings can be further used for vanadium extraction or as building materials for resource utilization.
II. Equipment Structure (Typical Configuration)
Furnace Body: Refractory lining of magnesia-carbon / alumina-magnesia material resistant to high temperature and erosion, equipped with water cooling system and intelligent temperature control.
Electrode System: DC graphite electrodes (hollow / solid), adjustable up and down to ensure stable arc and low loss; the furnace bottom is used as conductive anode.
Power Supply System: Rectifier transformer + DC power supply to provide stable DC current, with a high power factor (up to 0.95–0.98).
Feeding / Tapping / Deslagging: Continuous / semi-continuous feeding; alloy and molten slag are discharged intermittently through special tapping hole and deslagging hole respectively.
Flue Gas Purification: Secondary combustion of high-temperature flue gas (mainly CO) + waste heat recovery + dust removal and desulfurization to meet emission standards and recover energy.
Feeding: Quantitative feeding into the DC furnace.
Reduction Smelting: At a high temperature of 1500–1700℃, vanadium and iron oxides are reduced to metals by carbon to form vanadium-iron alloy; impurities such as titanium enter the slag phase.
Slag-Iron Separation: Alloy sinks to the bottom and molten slag floats up, with iron tapping and deslagging conducted separately.
Product Treatment:
Vanadium-iron alloy: Cooled and crushed for sale as metallurgical raw material.
Vanadium-rich slag: Further used to extract vanadium pentoxide (V₂O₅); or utilized as cement admixture, road base material, etc.
Flue Gas Treatment: CO combustion for waste heat recovery, flue gas purified to meet emission standards.
IV. Technical Advantages (vs. Traditional Processes)
Comparison Items
DC Furnace for Vanadium Iron Slag
Traditional AC Arc Furnace / Converter
Heat Source Characteristics
DC arc, directional and high energy density
AC arc, prone to arc deflection and scattered energy
Thermal Efficiency
High (≥85%), low power consumption per ton of slag
Relatively low, high power consumption
Metal Recovery Rate
Vanadium recovery rate over 85%, iron recovery rate over 98%
Relatively low recovery rate
Electrode Consumption
Low (over 30% lower than AC furnace)
High
Impact on Power Grid
High power factor, no harmonic interference
Large harmonics, requiring reactive power compensation
Environmental Performance
Flue gas recyclable for energy, low secondary pollution
High energy consumption, complex flue gas treatment
Adaptability
Suitable for low-grade vanadium slag and solid waste with complex components
High requirements for raw materials
V. Typical Applications and Cases
Core Applications: Reduction, vanadium extraction, iron extraction and resource utilization of vanadium-iron alloy smelting slag, vanadium-titanium magnetite smelting slag and low-grade vanadium slag.
Representative Cases: 3000KVA / 1500KVA DC furnaces for vanadium iron slag treatment customized by industrial furnace manufacturers, which have been put into production and operation, realizing efficient resource utilization of vanadium iron slag with qualified vanadium and iron recovery rates.
Recycled Products: Vanadium-iron alloy, vanadium pentoxide, cement admixture, road base material, glass-ceramics, etc.
Processing capacity: 30–50 tons of vanadium iron slag per day for 3000KVA model
Electrode: Graphite electrode (φ300–600mm)
Operating voltage: 100–300V
Power factor: 0.95–0.98
Vanadium recovery rate: ≥85%; Iron recovery rate: ≥98%
VII. Summary
DC furnace for vanadium iron slag treatment is ideal equipment for realizing reduction, harmlessness and high-value utilization of vanadium iron slag, especially suitable for vanadium-titanium industry and metallurgical solid waste resource utilization scenarios. Its core value lies in: efficiently recovering valuable metals such as vanadium and iron, while converting tailings into usable resources, significantly improving economic benefits and environmental performance.
Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. is a high-tech enterprise specialized in the research, design, and manufacturing of various industrial furnaces, including AC and DC steelmaking electric arc furnaces, ladle refining furnaces, ferroalloy ore thermal furnaces, ferroall... Shaanxi Chengda Industrial Furnace Manufacturing Co., Ltd. is a high-tech enterprise specialized in the research, design, and manufacturing of various industrial furnaces, including AC and DC steelmaking electric arc furnaces, ladle refining furnaces, ferroalloy ore thermal furnaces, ferroall...
