Introduction
In electric arc furnace (EAF) steelmaking, controlling production cost is a key concern for steel plants. Among all cost factors, electricity consumption and alloy additions play a major role.
This case study explains how Silicon Carbide 88 (SiC 88) can reduce total steelmaking cost by:
- Providing additional heat through exothermic reactions
- Replacing part of traditional alloys such as ferrosilicon
- Improving overall process efficiency
Why SiC 88 Works in EAF Steelmaking
Silicon carbide participates in metallurgical reactions inside the furnace:
SiC + O₂ → SiO₂ + CO + Heat
This reaction releases heat during the steelmaking process, which helps:
- Reduce electricity consumption
- Accelerate melting
- Improve thermal efficiency
At the same time, SiC provides both silicon (Si) and carbon (C), partially replacing other additives.
Comparative Case Study: 50-Ton EAF
Production Conditions
Furnace capacity: 50 tons
Steel grade: Carbon steel
Original additive: Ferrosilicon (FeSi 75%)
New additive: Silicon Carbide 88 (SiC 88)
Before Optimization (Using Ferrosilicon Only)
| Item | Value |
|---|---|
| FeSi consumption | 10 kg/ton steel |
| FeSi price | $1,300/ton |
| Cost per ton steel | $13.00 |
Electricity consumption:
Average: 500 kWh/ton
Electricity cost: $0.10/kWh
Cost: $50.00/ton
👉 Total cost (key part): $63.00/ton
After Optimization (Using SiC 88)
Changes:
Replace part of FeSi with SiC 88
Use SiC for both silicon supply and heat generation
| Item | Value |
|---|---|
| SiC 88 consumption | 8 kg/ton steel |
| SiC 88 price | $900/ton |
| Cost per ton steel | $7.20 |
Reduced FeSi usage:
New FeSi: 4 kg/ton
Cost: $5.20
👉 Total alloy cost: $12.40 → $12.40
Electricity Reduction
Due to exothermic reaction of SiC:
Electricity saving: 20 kWh/ton
Cost saving:
👉 20 × $0.10 = $2.00/ton
Total Cost Comparison
| Item | Before (FeSi) | After (SiC 88) |
|---|---|---|
| Alloy cost | $13.00 | $12.40 |
| Electricity cost | $50.00 | $48.00 |
| Total cost | $63.00 | $60.40 |
Final Saving
👉 Saving per ton steel: $2.60
For a 50-ton furnace:
👉 Total saving per heat: $130
For monthly production (example: 10,000 tons):
👉 Monthly saving: $26,000
Key Advantages of Using SiC 88
1. Lower Electricity Consumption
Exothermic reaction reduces power demand in EAF.
2. Reduced Alloy Cost
Partially replaces ferrosilicon and carbon additives.
3. Improved Process Efficiency
Faster melting and better thermal balance.
4. Better Cost Control
More predictable and stable production cost.
When Should You Use SiC 88?
SiC 88 is especially suitable when:
- Electricity cost is high
- Production scale is large
- Stable cost control is required
- Partial replacement of FeSi is acceptable
Calculation Formula (For Your Own Plant)
You can estimate savings using this formula:
Saving per ton = (FeSi reduction × FeSi price difference) + (Electricity saving × power cost) - SiC cost
Example:
- Electricity saving = 20 kWh
- Power cost = $0.10
- SiC vs FeSi cost difference included
👉 Result ≈ $2–3 per ton
Conclusion
This case study shows that Silicon Carbide 88 is not just a material replacement, but a practical way to reduce total steelmaking cost.
By combining:
- Heat generation
- Silicon supply
- Cost efficiency
SiC 88 provides a measurable economic advantage in EAF operations.
Get Technical Support and Price
Looking to reduce your steelmaking cost with Silicon Carbide 88?
Send us:
- Furnace type
- Steel grade
- Current additive usage
- We can provide:
- Cost calculation
- Recommended dosage
- Latest price
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ZHEN AN INTERNATIONAL CO.,LIMITED
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We are focused on building a dedicated team of professionals across the globe. At ZhenAn, we are committed to provide complete solutions by delivering the "right quality & quantity" to suite our customer's processes.
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