@@winchesterdude5368 yes indeed, same here, trouble caused by environment, heat, splashing of molten steel, impact from electrode, incontrollable arching and many more
this video in no way conveys the sound of an eaf, nor could any video could. its one of those things you have to be there to know. its not so much that its loud, which it is, but the sound also goes right thru you. its truly a thing to behold/experience
Someone I know who works at a steel plant says that you can wear 2 types of hearing protection (as is required around them) and still be deafened by it because of how it vibrates in your bones (and thus, your skull as well). It's also easy to misunderstand the tremendous size of these things, along with the gigantic amounts of power. The person I mentioned said anyone who wears any electronic device meant to keep them alive is ordered away from the electric arc furnaces upon starting them.
There’s a two station LMF between the EAF and lab, and I can sit there in a windowless building and *know* when they’re melting without actually hearing it.
i remember back then in engineering school we once visited a steel plant with one of these, max. batch size was around 100 tons. the plant guide had us pass by that thing a mere 20 meters away or so while active and to this day i remember it as one of the most violent things i have ever witnessed in my entire life. you can literally feel your bones and body fluids shaking...
I remember when I was the new guy 23 years ago. Our mill was a DC furnace. When they operate, they go off like artillery. AC furnaces are a pleasure to be around by comparison.
Just like a farm boy in the 1940s working on the railroad for the first time and seeing the Union Pacific's Big Boy or the C&O's Allegheny locomotives.
That was me on my first day as I was getting escorted in to the office to take the online safety courses lol. I got a hard hat and safety glasses in the parking lot and no ear plugs. It was awesome!
furnace operator has control of the electric power..they turn it down on cold scrap and ramp up as they melt in..today the configurations are variable and computerized.the noise is unmistakable full power on cold scrap and electrodes blow up..everybody in the melt shop and managers outside the meltshop can hear it and know what happened
I'm guessing the big chunky cables on the right are powering the electrodes? I like how the first few times an arc is struck, you can see them sway a little bit. Assuming that is due to some intense electromagnetic fields forming and collapsing rapidly as tens of thousands of amps flow intermittently. I work around some big and powerful electrical equipment but nothing on this scale. Would love to witness this in person.
Exactly correct. Your hair will stand up if you get too close to them. I considered metallurgy from mechanical engineering in college , so I did a summer internship in a mill. It is an expeince you are not ready for that first day. The heat and the noise set new limits of what you will ever experience. Then there is the dirt.
That's precisely it. th-cam.com/video/ywaTX-nLm6Y/w-d-xo.htmlsi=wBldmHQYSjo-x80U&t=565 This guy here wired a hundred car batteries in parralel to fry the crap out of large bolts and as the current peaks about 30,000 amps, you can see there cable fling around because of the magnetic forces.
I work in a steel mill, but not as close to the EAF as I’d like. I have yet to experience it in person. I have seen a KOBM furnace operate, and they’re equally as cool. Some people would be amazed at the scale of the parts of the process of making steel.
Most of the time yes it is with hydraulics.. although the factories in Russia and china typically utilize another system where there is a chain or a rope that leads to about 20 stationary bikes with pulleys and a bunch of chinamen pedal really fast when actuating the graphite electrodes. Usually, not always, one controls the switch gate, that’s what they call it, a switch gate and they can make the electrodes rise and lower
Yes, some old plant still used the old technology or if the furnace capacity small and the electrode weight were light, usually it can used AC motor as the actuators
They will have a direct hookup to the nearest plant. They usually have to tell said plant operators that they're going to be doing a heat before they actually do it, too, just so they're ready.
@@phuturephunk crazy! It’s amazing that there’s metal factories that use all that power and yet somehow the electric company stops it from dropping or affecting any customer’s power.
@@EphemeralProductions At least in the UK they usually get cheaper rates in return for agreeing to be cut off if the grid is in trouble too, there are some nice power prioritisation systems going on - network frequency management is fascinating :)
At my plant, with around 130t per heat. The electrode could stand around 100-150 heats, but it also depends on the scrap conditions, when it hitting the scraps or the electrodes controls doesn't works
yeah haha the voltage is super low, i have litteraly measured that with a fluke 117 directly, i work as a regulation/measurement/automation maintenence person so when the electrodes don't wanna go down or "wiggle" up and down too much, they call me. Last time, the voltage measurement convertor (36v AC to 4-20ma DC) for electrode 1 had died, but I had to check the step down measurement transformer, so there I went and measured. Gotta love Fluke quality, and accuracy, you can measure those miliamps as well as those hundreds of volts. Of course you tell the operator to put the power to the lowest level first, you don't wanna play with that stuff :)
You only measure the output from the VT or CT (step down transformer), from both of them will be connected to the sensor transducer for measuring the current and the voltage, and most sensor the output will be 4-20 mA, it'll be feedback for the automatic regulation. The plant in the video is using hydraulic system as the actuators
@@windshield11 I believe you are the expert, both means in my statement was for measuring the actual I and V, and the actual regulations inside the PLC is the impedance (Z), the achieve the good Z and the arch length inside the furnace, it will prevent the possibility the arch hit the others conductors, such as steel pipes, etc
@@Digidi4 not exactly the same, the smell is more "dry", mostly the furnace dust already consist of another material, like lime stone, so not pure metal
Sometimes it's happenings, during the first arch and many dust from the sponge iron or scrap, but after several arching, the steel become molten and ready to tapping
@@FixedFace yes, it might be true, it's an old plant, the automation control also still used the old technology, and if you compare to the new plant, it'll looks so much different, the holes between the electrode which is covered by refractory cement also need to be considered why the flash and dust coming out from the EAF.
PT KRAKATAU STEEL?? I have seen this video from my friend when he was working at a smelting factory owned by PT. KRAKATAU STEEL Yakin aku njir ini milik PT KRAKATAU STEEL
It's a conveyor area for the raw materials, such as sponge iron & limestone, for continuous feeding to the eaf, it's safe to work around that area. Sometimes the material wasn't at center area, so they push it several times
I thought I had brain damage at first but then I replayed the video and the radio chatter is definitely Indonesian. I might have inspected this mill in a previous life.
I love the fact that all melt shops look almost identical, the yellow handrails, dirty floor, dark dirty dungeon of a place
Nice to hear from person who has experience the same condition at melt shops 😁
Yep, millwright here. Fixed many water leaks, hydraulics, and welded all over one of them
@@winchesterdude5368 yes indeed, same here, trouble caused by environment, heat, splashing of molten steel, impact from electrode, incontrollable arching and many more
I've been to many steel Mills like this and AK steel in Dearborn Michigan is by far the worst
They could definitely improve the draft of the off gasses.
this video in no way conveys the sound of an eaf, nor could any video could. its one of those things you have to be there to know. its not so much that its loud, which it is, but the sound also goes right thru you. its truly a thing to behold/experience
Someone I know who works at a steel plant says that you can wear 2 types of hearing protection (as is required around them) and still be deafened by it because of how it vibrates in your bones (and thus, your skull as well).
It's also easy to misunderstand the tremendous size of these things, along with the gigantic amounts of power.
The person I mentioned said anyone who wears any electronic device meant to keep them alive is ordered away from the electric arc furnaces upon starting them.
That and the HEAT.
There’s a two station LMF between the EAF and lab, and I can sit there in a windowless building and *know* when they’re melting without actually hearing it.
i remember back then in engineering school we once visited a steel plant with one of these, max. batch size was around 100 tons. the plant guide had us pass by that thing a mere 20 meters away or so while active and to this day i remember it as one of the most violent things i have ever witnessed in my entire life. you can literally feel your bones and body fluids shaking...
When I worked in a steel mill, the EAF is so loud it vibrated the floor you was standing on ! Until you stand beside one, you don't have a clue ! 😁
Yes, indeed
I heard it’s almost like being punched in the chest if you’re standing close
@@ethanl440 That is true, because that is exactly what is happening with the air XD
Imagine being the new guy and seeing this for the first time.
Lmao 🤣
I remember when I was the new guy 23 years ago. Our mill was a DC furnace. When they operate, they go off like artillery. AC furnaces are a pleasure to be around by comparison.
Just like a farm boy in the 1940s working on the railroad for the first time and seeing the Union Pacific's Big Boy or the C&O's Allegheny locomotives.
That was me on my first day as I was getting escorted in to the office to take the online safety courses lol. I got a hard hat and safety glasses in the parking lot and no ear plugs. It was awesome!
furnace operator has control of the electric power..they turn it down on cold scrap and ramp up as they melt in..today the configurations are variable and computerized.the noise is unmistakable full power on cold scrap and electrodes blow up..everybody in the melt shop and managers outside the meltshop can hear it and know what happened
EAF operator pretty much pushes a few buttons nowadays, it's all automated.
Now THAT is all things Heavy Metal!
I'm guessing the big chunky cables on the right are powering the electrodes? I like how the first few times an arc is struck, you can see them sway a little bit. Assuming that is due to some intense electromagnetic fields forming and collapsing rapidly as tens of thousands of amps flow intermittently. I work around some big and powerful electrical equipment but nothing on this scale. Would love to witness this in person.
Exactly correct. Your hair will stand up if you get too close to them. I considered metallurgy from mechanical engineering in college , so I did a summer internship in a mill. It is an expeince you are not ready for that first day. The heat and the noise set new limits of what you will ever experience. Then there is the dirt.
That's precisely it.
th-cam.com/video/ywaTX-nLm6Y/w-d-xo.htmlsi=wBldmHQYSjo-x80U&t=565
This guy here wired a hundred car batteries in parralel to fry the crap out of large bolts and as the current peaks about 30,000 amps, you can see there cable fling around because of the magnetic forces.
Makes the Martians Heat Ray in HG Wells War of the Worlds look like a cigarette lighter!
i am currently in electric arc furnance site (JSPL raigarh). the sound is life taking.
I have been to JSPL raigarh for business trip, your workers at EAF were amazing, less downtime and fast respond
Epic Beyblade battle is going inside there
Keep watching another video
I feel a strange sense of familiarity. I've been here before. Oh yeah, UAC Mars Base.
I work in a steel mill, but not as close to the EAF as I’d like. I have yet to experience it in person. I have seen a KOBM furnace operate, and they’re equally as cool. Some people would be amazed at the scale of the parts of the process of making steel.
Is this the place where Zeus makes his lightning strikes?
I worked for a company that made carbon electrodes. Pretty cool to see in action.
Kept thinking it was gonna blow at some point had that experience once
Crazy controlled explosion
this is SO COOL
Thanks
Maximum level of industrial metal this is.
Krakatau steel EAF 9 ?
High Voltage Rock n Roll.
Mantap lurr
I think , this is at Krakatau steel company , right ?? The employee and sound from HT is indonesian
Looks like the set of the next Alien movie.
Damn thats violent
It's just the beginning
Regarding the process by which the electrodes are lowered and raised, is that by means of hydraulics? Thanks in advance 😌
Yes by hydraulic cylinder system
Most of the time yes it is with hydraulics.. although the factories in Russia and china typically utilize another system where there is a chain or a rope that leads to about 20 stationary bikes with pulleys and a bunch of chinamen pedal really fast when actuating the graphite electrodes. Usually, not always, one controls the switch gate, that’s what they call it, a switch gate and they can make the electrodes rise and lower
Yes, some old plant still used the old technology or if the furnace capacity small and the electrode weight were light, usually it can used AC motor as the actuators
Its Go Time Guys ! Remember those Days Well !😁✌
How many Amps are going through those electrodes?
Is that big pipe coming up out of the floor to the left of the furnace what they use to suck the fumes out?
Yes it's called dedusting system, fume, dust, will be suck and filtered to get a good waste air before releasing to the outside air
Thats one hella welding machine lol
How much current is to be passed through those electrodes to start melting those?
Secondary parts around 600A, depend on the OLTC change by the operation
This is in Indonesia, right?
Awesome
Thanks 👍
@@TFHC where is this??which country?
@@canismajoris7659 india
Hell on earth in there !
That's just purgatory lol
real deal here!!
Hell on EARTH, is best way to describe it. during "BURN-IN".
1:15 that's looks like mini volcano
source video ?!
Terlihat tidak asing bagi saya.
Whole place hums at 60Hz
That’s 50 hz. :)
Just watch out for those head crabs.
Are the explosions that start around 1:15 normal?
Yeah, maybe yes maybe not, it depends on the scraps quality, sometimes, the scrap was to big and dusty
What supplies the electricity?? Is there an on site generator that’s then run through transformers or is it pulled in from the mains?
We using directly from power plants
They will have a direct hookup to the nearest plant. They usually have to tell said plant operators that they're going to be doing a heat before they actually do it, too, just so they're ready.
@@phuturephunk crazy! It’s amazing that there’s metal factories that use all that power and yet somehow the electric company stops it from dropping or affecting any customer’s power.
@@EphemeralProductions At least in the UK they usually get cheaper rates in return for agreeing to be cut off if the grid is in trouble too, there are some nice power prioritisation systems going on - network frequency management is fascinating :)
@@TFHC I'd like to see how those would run on solar panels.
Something so ugly yet so intriguing
Is high voltage
me sitting on the potty in the AM
Those electrodes must be very strong how long do they last does anyone know
At my plant, with around 130t per heat. The electrode could stand around 100-150 heats, but it also depends on the scrap conditions, when it hitting the scraps or the electrodes controls doesn't works
The amount of power involved... that's what, ballpark 500V, maybe 600V and 30-40,000A
yeah haha the voltage is super low, i have litteraly measured that with a fluke 117 directly, i work as a regulation/measurement/automation maintenence person so when the electrodes don't wanna go down or "wiggle" up and down too much, they call me. Last time, the voltage measurement convertor (36v AC to 4-20ma DC) for electrode 1 had died, but I had to check the step down measurement transformer, so there I went and measured. Gotta love Fluke quality, and accuracy, you can measure those miliamps as well as those hundreds of volts. Of course you tell the operator to put the power to the lowest level first, you don't wanna play with that stuff :)
You only measure the output from the VT or CT (step down transformer), from both of them will be connected to the sensor transducer for measuring the current and the voltage, and most sensor the output will be 4-20 mA, it'll be feedback for the automatic regulation. The plant in the video is using hydraulic system as the actuators
@@TFHC Actually I measured both sides? I do know what I measured bro
@@windshield11 I believe you are the expert, both means in my statement was for measuring the actual I and V, and the actual regulations inside the PLC is the impedance (Z), the achieve the good Z and the arch length inside the furnace, it will prevent the possibility the arch hit the others conductors, such as steel pipes, etc
I weld the copper shoes thst the electroes get there power from
When we go green, it will take every wind turbine in the country to power that melt pot.
Yes indeed, only coal power plant can fulfilling the power consumption of melting steel industry
Translation:
Boss: Product sales not doing well. I hear people make more money from youtube these days.
Looks like the set of terminator
That would be a ladle transfer car.
The language of the operator sounds familiar,
Hmmm... I guess, they spoke in Indonesia
So that, probably this video is from Krakatau Steel industry
masyaAllah luar biasa keren 👍👍👍
Thank you soo much
@@TFHC you're welcome! 😀
Imagine showing this to some caveman
Wait for the electricity bill
One million a month, if you are lucky.
Krakatau steel furnece 9 lur
Step graphite - what are you doin
I'm getting Chernobyl effects lol
Hey there why does this machine have three elctrodes? Isnt electricity binary?
It's a three phase electrode EAF type
What power/electricity kW etc needs this to startup?
On a 100 ton EAF it's about 50 - 70 mega watts
ow! @@michaelgreaves2375
and still not enough power for my pc running minecraft with shaders
That's enough youtube for today i guess.
😂👌
Has someone Commited a crime. A lot of sirens going🤣
1:08
This is in Italy
Which city? Which plant?
I bet this smells nice
Smell like iron 😁
@@TFHC does it smell like when you weld?
@@Digidi4 not exactly the same, the smell is more "dry", mostly the furnace dust already consist of another material, like lime stone, so not pure metal
It smells like pastry if you go where the refractory is baking on a tundish.
4K lol!
1:10
haha furnace goes brrrrrrrrr
Thanks brother
1:18 i have no idea about this technology. that’s not supposed to happen, right?
Sometimes it's happenings, during the first arch and many dust from the sponge iron or scrap, but after several arching, the steel become molten and ready to tapping
@@TFHC
thanks for the feedback! to me as as a layman it looks "out of control", as if the machine is breaking and blowing up any moment
@@FixedFace yes, it might be true, it's an old plant, the automation control also still used the old technology, and if you compare to the new plant, it'll looks so much different, the holes between the electrode which is covered by refractory cement also need to be considered why the flash and dust coming out from the EAF.
PT KRAKATAU STEEL??
I have seen this video from my friend when he was working at a smelting factory owned by PT. KRAKATAU STEEL
Yakin aku njir ini milik PT KRAKATAU STEEL
Iya bos itu Krakatau steel SSP2 furnece 9
@@muhitaja2561 EAF 9 mungkin maksudnya mas
@@FX_MANOR iya bos
@@FX_MANOR itu tidak asing bagi saya
Dude, what about the guy in the top left hand corner? Why tf is he working there?!
It's a conveyor area for the raw materials, such as sponge iron & limestone, for continuous feeding to the eaf, it's safe to work around that area.
Sometimes the material wasn't at center area, so they push it several times
I thought I had brain damage at first but then I replayed the video and the radio chatter is definitely Indonesian.
I might have inspected this mill in a previous life.
What we have right here is a massive fkn pot of short circuit angry pixies turning steel into liquid