Magatherm_25012012:Layout 1 1/25/2012 12:12 PM Page 2

Worldwide Installation

Argentina

Kenya

Azerbaizan

Malaysia

Bolivia

Mexico

Botswana

Nepal

Bhutan

Nigeria

Bangladesh

Pakistan

Brazil

Poland

Cuba

Saudi Arabia

Egypt

South Africa

France

Sudan

Ghana

Tanzania

Georgia

Taiwan

India

Tunisia

Iran

U.A.E.

Iraq

Uganda

Kuwait

Yemen

Corporate Office
Plot-L1, Block-GP, Sector-V, Salt Lake City, Kolkata-700 091, India, Phone: +91 33 2357 7352/ 3493, Fax: +91 33 2357 7757
Works
EMT Megatherm Pvt.Ltd.
1, Taratala Road, Kolkata-700 088, India, Phone: +91 33 2401 4234/4235, Fax: +91 2410 3246
E-mail: sales@megatherm.com, Web: www.megatherm.com

Magatherm_25012012:Layout 1 1/25/2012 12:12 PM Page 4

Modern Electric Steelmaking

Waste Gas

Filters

Preheating

Filters

Charge Materials

Electrodes

Off Gas

Air

Burners
Injection Lance

Cooling Water

Oxygen Lance
Slag
Tank

Steel

Over the years, new processes and new equipment have been introduced in modern
steelworks, which aim at reducing operating costs and improving efficiency of Electric
Arc Furnaces. Some of these are

The Company
In 1989 as we sparked-off, we banked upon our troupe of Electro Thermal
Processing experts and the capital of experience that we had gathered since
the 70s. We made our presence felt across Steel, Foundry, Forging and
various other Metal Working Sectors. Driven by strong commitment towards
customer services, product performance and continuous in-house Research
and Development, the Company within in a short span of time has
contributed over 5000 MW in aggregate of Electro Heating Equipment.
Today, Megatherm is recognized and preferred by its ever-extending list of
domestic and international clientele. Our installation are spread over the
globe in countries, such as Brazil, Argentina, Mexico in Latin America; South
Africa, Nigeria, Egypt, Kenya in Africa; Georgia, Kazakhstan, Azerbaijan,
Iran in Central Asia; India, Pakistan, Bangladesh, Malaysia in South Asia,
Kuwait, Saudi Arabia, U.A.E., Yemen in Middle East Asia; Poland, France,
Germany in Europe to name a few.
Being certified as an ISO 9001:2000 Company, the name Megatherm today
is synonymous to quality.

Ultra High Power (UHP) Transformers, power levels of 700 to 1000 KVA / Ton.

High Impedance operation with higher secondary voltages and lower current, thus
resulting in stable arcing, longer arc length and lower electrode consumption.

Better utilization of energy by supplementing electrical energy with energy from

other sources, alternative being Oxy Fuel Burners, Oxygen Lancing, Carbon &
Oxygen Lancing.

Eccentric Bottom Tapping.

To reduce thermal losses by a proper design of water-cooled panels.

Computer control to optimize electric power programming and automatic tap

changing based on furnace condition and power demand. More complex systems
provide control of metallurgical parameters (tap temperature and timing of process
events), data logging and least-cost charge calculations, etc.

Scrap preheating to recover energy from furnace waste gases.

Note: All of these developments may be applied to any one furnace, nor they are
necessarily complimentary to each other. It is for each steelmaker to establish which
development or combination of developments is of greatest benefit in their local
conditions.

Magatherm_25012012:Layout 1 1/25/2012 12:12 PM Page 6

Electric Arc Furnace

Typical Layout

An Electric Arc Furnace is defined in terms

of its shell diameter and transformer rating.
The shell diameter for a given furnace is
largely chosen as a function of tap weight
required and the steel making practise to be
adopted, the current trend is towards larger
shell diameter for a given weight. The choice
of tap weight is influenced by such factors
as dedication to continuous casting
machine, productivity requirement and
capital costs.

Layout shows Arc Furnace equipped with Eccentric Bottom Tapping Device.

1
D

Legend

The transformer size determine the rate at which furnace can melt ferrous raw materials. The
following diagram gives the various inputs & outputs in an Electirc Arc Furnace.

4
3

B
A

Inner Diameter
of Furnace
Shell (mm)

Nominal
Capacity
(Ton)

Continuous Rated
Capacity of
Transformer (KVA)

Electrode
Diameter

MT - 2S

2000

1500

6"

MT - 5S

2440

2000
2500

8"

MT - 10S

3350

10

5000
6000

12"

MT - 15S

3450

15

6000
7500

12"

MT - 20S

3650

20

9000
12000

14"

MT - 25E

4000

25

15000
18000
21000

16"

30

18000
21000
24000

16"

35

21000
24000
28000

16"
16"
18"

40

28000
30000
32000

18"

45

32000
36000

18"
20"

Model

MT - 30E

MT - 35E

MT - 40E
MT - 45E

4200

4300

4400
4600

MT - 50E

4800

50

35000
40000

MT - 60 E

5100

60

42000
48000

20"

MT - 70E

5300

70

50000
60000

20"

Transformer

High-Voltage Switchgear

Hydraulic Unit

Pressure Vessel

Main Control Desk

Electric Control

Tilting Console

Model

Inner Diameter of
Furnace Shell (mm)

MT - 2S

2000

2880

4880

2000

5015

MT - 5S

2440

2880

4880

2000

5300

MT - 10S

3350

4318

6325

2007

7470

MT - 15S

3450

4318

6325

2007

8310

MT - 20S

3650

4344

6020

1676

9000

MT - 25E

4000

5327

7848

2521

10000

MT - 30E

4200

5327

7848

2521

10000

MT - 35E

4300

5327

7848

2521

10000

MT - 40E

4400

7848

10363

2515

10000

MT - 45E

4600

7848

10363

2515

10000

MT - 50E

4800

7348

9858

2510

10000

MT - 60 E

5100

7060

10310

3250

10000

MT - 70E

5300

6960

10110

3150

10000

Magatherm_25012012:Layout 1 1/25/2012 12:12 PM Page 8

Electrode Regulation System

Megatherm also provides High-Speed Closed Loop Digital Electrode Regulation System.
The electrode regulator controls through hydraulic valves manual or automatic movement
of electrode arms.

Winch

The system is implemented in dedicated standard PLC. The set up, tuning or monitoring is
implemented in PC.

AC or DC
Drive

To achieve, Impedance Control, a proportion of the arc voltage and a proportion of arc
current flowing in the arc are compared thus giving measured impedance value. Measured
impedance value is compared with the set value determined based on:
n
System Impedance
n
Furnace Impedance
n
Transformer Impedance
n
Primary Voltage
n
Tap Changer Position
n
Reactor Tap Position
n
Current Setting

Motor Gear Reducer

Spout Type

Hydraulic

Valve Control

The resultant gives the error impedance signal. The electrical error signal is amplified and is
fed to hydraulically operated proportional control valve to raise / lower the electrode arms
thus resulting in auto setting of electrode to operate at set impedance.

EBT Type

Arc Furnace Heat Balance

The heart of Electric Arc and Ladle Refining Furnace is the electrode regulator. The system
determines the efficiency of the furnace as it effects the consumption of power, electrodes
and refractories.
There are two basic methods of moving the electrode arms, i.e thyristorised controlled Winch
unit or Hydraulic regulation. Both are capable of operating efficiently. For bigger furnaces
hydraulic regulation is preferred, whereas for smaller units either of the two is employed.

In an arc furnace energy can be supplied from a variety of sources as shown in the table
below. The energy distribution is highly dependent on local material and consumable costs
and is unique to the specific melt shop operation. A typical balance for Ultra High Power
Furnace and low or medium power is indicated here as under:
Energy

Area

UHP Furnace
Power Furance

Low to Medium

Electrical Energy

50 - 60%

75 - 85%

Burners

5 - 10%

Chemical Reactions

30 - 40%

15 - 25%

100%

100%

Steel

55 - 60%

50 - 55%

Slag

8 - 10%

8 - 12%

Cooling Water

8 - 10%

5 - 6%

Miscellaneous

1 - 3%

17 - 30%

17 - 28%

7 - 10%

100%

100%

OLTC

Inputs

Arc
Impedance
Measure
Unit

A-1/0

Hydraulic
Control
System

Total Inputs

A-1/0

Outputs

P.C.
P.L.C. Unit

Off Gas
R.C.D.

0/1-112 0/0-64

A/0-4

A/1-2

Total Outputs

Magatherm_25012012:Layout 1 1/25/2012 12:12 PM Page 10

General Arrangement Drawing

Ladle Refining Furnace

28
16

23

15

22

14

20
13
27

10

PLATFORM

19

12

11

Legend

03

Ladle Refining is a post steel making technological operation, performed in the ladle prior
to casting with the purpose of desulphurization, degassing, temperature & chemical
homogenization, deoxidation etc.
The normal LRF cycle lasts 40 50 minutes depending upon the aim and final chemistry
and desired temperature rise.

09
02
01

01
02
03
04
05
09
10
11
12
13
14
15
16
17
18
19
20
22
23
24
25
26
27
28

Rocker Base
Column Side Rocker
Far Side Rocker
Bracket For Tilt Cylinder
Tilt Cylinder
Swivel Arrangement
Slew Platform
Substructure
Slew Roller Assembly
Column Guide Roller Assembly
Back Structure
Gantry Arm
Roof Lift Assembly
Column Cylinder Base Frame Assembly
Column Assembly
Shell -Bottom Part
Shell Top Part
Water Cool Panel Assembly
Water Cool Roof Assembly
Electrode Arm Assembly - Middle
Electrode Arm Assembly - Right Hand
Electrode Arm Assembly - Left Hand
Shell Lining Details
Maintenance Platform- Under Client Scope

18

04

Benefits

05

17

ELEVATION

55 SLEW

26

The increased oxidation (reduced oxygen

level) produces a very clean steel, good
desulphurization (by injection of Casi wire &
fluxes) and a decrease in non metallic
inclusions (removed by gentle stirring), result better quality of steel

Power
Injection Lance

Graphite
Electrodes
Fume Extraction

Addition
Hopper

The temperature and composition of melt can

be strictly controlled;

Better Homogenization Temperature &

composition are equalized by stirring

The oxidized alloying elements in the slag can

be returned to the melt by reduction;

Large amount of alloying material can be added to produce high alloyed steel;

The melt can be held in ladle for long period of time and multiple ladles can be used to
pour a single large ingot;

The productivity of melting furnace is increased.

24
25

PLAN

Argon

Magatherm_25012012:Layout 1 1/25/2012 12:12 PM Page 12

Ladle Refining Furnace Data

Ladle Furnace with Cover Arragment

S.No.

Capacity

Ladle Dia. At
bath level (mm)

Capacity of
Transformer
(Nominal)

Electrode
Diameter

10

950

2000

8"

12

1060

2500

8"

15

1160

3000

8"

18

1270

3600

10"

25

1500

5000

12"

30

1630

6000

12"

35

1761

7000

12"

40

1882

8000

14"

45

1996

9000

14"

10

50

2104

10000

16"

11

60

2306

12000

16"

12

70

2491

14000

16"

Legend
1
2
3
4
5

Ladle
Ladle Car
Cover
Electrode
Electrode Holding Arm

6
7
8
9
10

Cover Lifting Arrangement

Water Cooled Cables
Busbar Arrangement (L. T. Side)
Current Transformer
Transformer

10

1
2