An electromagnetics-temperature-component multi-physical coupled model for electric furnace in calcium carbide smelting process

A transient three-dimensional (3D) mathematical model is established to analyze electromagnetics-temperature-component multi-physical field distribution in calcium carbide (CaC₂) smelting process in this paper. The electromagnetic field is solved by Maxwell's equations using the finite element method. The temperature field and phase change are modeled by the enthalpy equations. The chemical reaction process is built by reaction kinetics equations. The numerical modeling method is verified against data from literature. The results show that multi-physical fields are strongly coupling and uneven in electric furnace. Therefore, the higher temperature and product are mainly distributed in the upper layer of center zone. Large-capacity electric furnace is qualified with significant advantage in increasing output. When three-phase alternating current increases from 10,000 A to 14,000 A, the volume of CaC₂ and molten CaC₂ pool increases by 51.6% and 52.3% at the end of smelting process, respectively. However, it also increases the temperature in furnace, which has a negative effect on the safe production. The mathematical model established in this paper can accurately reflect electromagnetics-temperature-component multi-physical field distribution, and can provide guidance for the design and development of high-efficiency calcium carbide electric furnace.