Modeling and Energy Efficiency Analysis of Ferro-Silicon Submerged Arc Furnace Under Flexible AC Power Supply in Balanced Steady State

Submerged Arc Furnace (SAF) is crucial for smelting ferroalloys, calcium carbide, and industrial silicon. However, the Traditional AC Power Supply and Distribution System (TAPSDS) faces challenges, including high energy consumption, low efficiency, and uneven distribution of power. This study conducts an energy consumption analysis based on the actual parameters of a 33MVA ferrosilicon SAF. Initially, the research develops a comprehensive energy consumption model for the TAPSDS, encompassing transformers, short-net, electrodes, SAF loads, and reactive power compensation devices. The study introduces an innovative Flexible AC Power Supply and Distribution System (FAPSDS). This system combines multi-winding phase-shifting transformers with modular flexible power units. Its design enhances flexibility and control over smelting voltages, aiming to improve energy efficiency significantly. The paper details the principal circuit configuration, control system, and operational strategies of the FAPSDS. It develops a detailed energy consumption model tailored for the FAPSDS when applied to the 33MVA ferrosilicon SAF. Comparative simulations using MATLAB/SIMULINK showcase the benefits of the FAPSDS. Compared with TAPSDS and TAPSDS enhanced with reactive power compensation technology (TAPSDS-RPCT), the energy consumption in SAF operation was reduced by 7.86% and 4.02%, respectively, and the smelting production increased by 12.45% and 7.98%, respectively.