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Comprehensive Utilization of Electric Furnace Bottom Ash/Fly Ash by DC Electric Arc Furnace
DC electric arc furnaces (including single-electrode, double-electrode, and multi-electrode types) are high-efficiency equipment for the resourceful and harmless treatment of electric furnace bottom ash and fly ash. This technology realizes the separation of valuable metals, reduction of harmful substances, and recycling of molten slag, which is in line with the green development direction of the metallurgical industry.
1. Characteristics of Electric Furnace Bottom Ash/Fly Ash
Electric furnace bottom ash and fly ash are typical solid wastes in steelmaking processes, with complex components:
Waste Type
Main Components
Harmful Substances
Valuable Components
Bottom Ash
SiO₂ (20–35%), CaO (15–25%), Fe₂O₃ (10–20%), Al₂O₃ (5–10%)
Heavy metals (Pb, Zn, Cr), dioxins, chloride
Iron, rare metals (Cu, Ni), slag (recyclable as building materials)
Fly Ash
Carbon (15–30%), SiO₂ (25–40%), CaO (10–15%)
Fine dust, heavy metal oxides, dioxins
Carbon (recyclable as reducing agent), iron oxides
Key Problems to Solve: Heavy metal leaching, dioxin pollution, and low resource utilization rate.
2. Technical Principle of DC Electric Arc Furnace Treatment
DC electric arc furnaces use high-temperature plasma arcs (15,000–20,000℃) and strong electromagnetic stirring to treat bottom ash/fly ash through pyrolysis, reduction, melting, and separation processes:
Feeding & Preheating: Mix bottom ash, fly ash, and a small amount of reducing agent (coke powder) uniformly, and send them into the furnace. The flue gas waste heat preheats the materials to 500–800℃, realizing preliminary dehydration and dechlorination.
High-Temperature Reduction: DC arc generates a high-temperature zone of 1200–1600℃. Under the action of reducing agents, iron oxides in the waste are reduced to molten iron; heavy metals (Pb, Zn) are volatilized and collected through flue gas treatment systems.
Molten Slag Vitrification: Silica and calcium oxide in the waste form a stable glassy molten slag under high temperature, which encapsulates residual heavy metals and prevents leaching.
Phase Separation: Under electromagnetic stirring, the high-density molten iron sinks to the furnace bottom, and the low-density molten slag floats on the surface, realizing efficient separation of iron, slag, and harmful substances.
Harmful Substance Decomposition: High temperature (>1000℃) completely decomposes dioxins into harmless small molecules (CO₂, H₂O), avoiding secondary pollution.
3. Optimal DC Electric Arc Furnace Configuration for Waste Treatment
A double-electrode or four-electrode DC submerged arc furnace is preferred for large-scale treatment of bottom ash/fly ash, with the following customized configurations:
System
Customized Parameters
Electrode System
Graphite electrodes (diameter 500–800mm); independent lifting control to adjust arc length and temperature distribution
Power Supply System
Rated power 5–20MVA; DC voltage 400–800V; current stabilization control to adapt to low-grade waste materials
① Flue gas purification system: Bag dust removal + activated carbon adsorption + heavy metal condensation recovery; ② Molten slag granulation system: Water quenching to produce glassy slag particles
Heavy metal leaching; soil and groundwater pollution
Resource Utilization Rate
100% (iron, slag, heavy metals all recycled)
50–60% (only partial carbon/iron recovered)
0% (waste of resources)
Applicable Scale
Large-scale (10,000–100,000 tons/year)
Medium-scale (1,000–10,000 tons/year)
Small-scale
6. Application Cases & Implementation Notes
6.1 Typical Application Case
A steel plant in China adopted a 10MVA four-electrode DC submerged arc furnace to treat 50,000 tons of electric furnace bottom ash annually:
Treatment Cost: $80–100 per ton of waste.
Economic Return: Recovered 4,000 tons of molten iron, 45,000 tons of building slag, and 50 tons of lead-zinc alloy annually, with a total annual benefit of $1.2 million.
Environmental Benefit: Dioxin emission is 0.05ng TEQ/m³, which is 50% lower than the national standard.
6.2 Key Implementation Notes
Material Pretreatment: Crush bottom ash/fly ash to particle size ≤10mm, and remove large impurities (steel scraps, refractory fragments) to avoid electrode damage.
Reducing Agent Ratio: Control the addition amount of coke powder at 5–8% of the total material to ensure sufficient reduction of iron oxides without excessive carbon residue.
Temperature Control: Maintain the furnace temperature at 1300–1500℃; excessive temperature will increase energy consumption, while insufficient temperature will affect vitrification effect.
Flue Gas Treatment: Equip a dedicated heavy metal condensation device to recover volatile Pb/Zn and avoid secondary pollution in flue gas.
7. Development Trends
Integration with Waste Heat Power Generation: Combine the furnace with a waste heat boiler to realize self-sufficiency of 30–40% of the furnace's electricity consumption.
Intelligent Control System: Use AI to monitor material composition, furnace temperature, and gas components in real time, and automatically adjust process parameters to optimize treatment effects.
Multi-Waste Co-Treatment: Expand the application scope to treat municipal solid waste incineration fly ash, hazardous waste, etc., realizing the synergistic disposal of multiple solid wastes.
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...
