Electric arc furnace in the context of "Foundry"

Slag is a by-product or co-product of smelting (pyrometallurgical) ores and recycled metals depending on the type of material being produced. Slag is mainly a mixture of metal oxides and silicon dioxide. Broadly, it can be classified as ferrous (co-products of processing iron and steel), ferroalloy (a by-product of ferroalloy production) or non-ferrous/base metals (by-products of recovering non-ferrous materials like copper, nickel, zinc and phosphorus). Within these general categories, slags can be further categorized by their precursor and processing conditions. Examples include blast furnace slags, air-cooled blast furnace slag, granulated blast furnace slag, basic oxygen furnace slag, and electric arc furnace (EAF) slag. Slag generated from the EAF process can contain toxic metals, which can be hazardous to human and environmental health.

Due to the large demand for ferrous, ferralloy, and non-ferrous materials, slag production has increased throughout the years despite recycling (most notably in the iron and steelmaking industries) and upcycling efforts. The World Steel Association (WSA) estimates that 600 kg of co-materials (co-products and by-products; about 90 wt% is slags) are generated per tonne of steel produced.

Electrification is the process of powering by electricity and, in many contexts, the introduction of such power by changing over from an earlier power source. In the context of history of technology and economic development, electrification refers to the build-out of the electricity generation and electric power distribution systems. In the context of sustainable energy, electrification refers to the build-out of super grids and smart grids with distributed energy resources (such as energy storage) to accommodate the energy transition to renewable energy and the switch of end-uses to electricity.

The electrification of particular sectors of the economy, particularly out of context, is called by modified terms such as factory electrification, household electrification, rural electrification and railway electrification. In the context of sustainable energy, terms such as transport electrification (referring to electric vehicles) or heating electrification (referring to heat pumps powered with solar photovoltaics) are used. It may also apply to changing industrial processes such as smelting, melting, separating or refining from coal or coke heating, or from chemical processes to some type of electric process such as electric arc furnace, electric induction or resistance heating, or electrolysis or electrolytic separating.

An open-hearth furnace or open hearth furnace is any of several kinds of industrial furnace in which excess carbon and other impurities are burnt out of pig iron to produce steel. Because steel is difficult to manufacture owing to its high melting point, normal fuels and furnaces were insufficient for mass production of steel, and the open-hearth type of furnace was one of several technologies developed in the nineteenth century to overcome this difficulty. Compared with the Bessemer process, which it displaced, its main advantages were that it did not embrittle the steel from excessive nitrogen exposure, was easier to control, and permitted the melting and refining of large amounts of scrap iron and steel.

The open-hearth furnace was first developed by German/British engineer Carl Wilhelm Siemens. In 1865, the French engineer Pierre-Émile Martin took out a licence from Siemens and first applied his regenerative furnace for making steel. Their process was known as the Siemens–Martin process or Martin–Siemens process, and the furnace as an "open-hearth" furnace. Most open hearth furnaces were closed by the early 1990s, not least because of their slow operation, being replaced by the basic oxygen furnace or electric arc furnace.

Pyroprocessing (from Greek Πυρος = fire) is a process in which materials are subjected to high temperatures (typically over 800 °C) in order to bring about a chemical or physical change. Pyroprocessing includes such terms as ore-roasting, calcination and sintering. Equipment for pyroprocessing includes kilns, electric arc furnaces and reverberatory furnaces.

Cement manufacturing is a very common example of pyroprocessing. The raw material mix (raw meal) is fed to a kiln where pyroprocessing takes place. As with most industries, pyroprocessing is the most energy-intensive part of the industrial process.

Steelmaking is the process of producing steel from iron ore and/or scrap. Steel has been made for millennia, and was commercialized on a massive scale in the 1850s and 1860s, using the Bessemer and Siemens-Martin processes.

Currently, two major commercial processes are used. Basic oxygen steelmaking (BOS) uses liquid pig-iron from a blast furnace and scrap steel as the main feed materials. Electric arc furnace (EAF) steelmaking uses scrap steel or direct reduced iron (DRI). Oxygen steelmaking has become more popular over time.

Non-ferrous extractive metallurgy is one of the two branches of extractive metallurgy which pertains to the processes of reducing valuable, non-iron metals from ores or raw material. Metals like zinc, copper, lead, aluminium as well as rare and noble metals are of particular interest in this field, while the more common metal, iron, is considered a major impurity. Like ferrous extraction, non-ferrous extraction primarily focuses on the economic optimization of extraction processes in separating qualitatively and quantitatively marketable metals from its impurities (gangue).

Any extraction process will include a sequence of steps or unit processes for separating highly pure metals from undesirables in an economically efficient system. Unit processes are usually broken down into three categories: pyrometallurgy, hydrometallurgy, and electrometallurgy. In pyrometallurgy, the metal ore is first oxidized through roasting or smelting. The target metal is further refined at high temperatures and reduced to its pure form. In hydrometallurgy, the object metal is first dissociated from other materials using a chemical reaction, which is then extracted in pure form using electrolysis or precipitation. Finally, electrometallurgy generally involves electrolytic or electrothermal processing. The metal ore is either distilled in an electrolyte or acid solution, then magnetically deposited onto a cathode plate (electrowinning); or smelted then melted using an electric arc or plasma arc furnace (electrothermic reactor).

Carbothermic reactions involve the reduction of substances, often metal oxides (O), using carbon (C) as the reducing agent. The reduction is usually conducted in the electric arc furnace or reverberatory furnace, depending on the metal ore. These chemical reactions are usually conducted at temperatures of several hundred degrees Celsius. Such processes are applied for production of the elemental forms of many elements. The ability of metals to participate in carbothermic reactions can be predicted from Ellingham diagrams.

Carbothermal reactions produce carbon monoxide (CO) and sometimes carbon dioxide (CO₂). The facility of these conversions is attributable to the entropy of reaction: two solids, the metal oxide (and flux) and carbon, are converted to a new solid (metal) and a gas (CO_x), the latter having high entropy.

Various types of electrical transformer are made for different purposes. Despite their design differences, the various types employ the same basic principle as discovered in 1831 by Michael Faraday, and share several key functional parts.