The Company

Va ib ha v Furna c es is a Com p a ny for Desig ning , Eng ineering ,& Sup p lying Steel Melting ,
Refining Furna c es for steel Ind ustries a nd Ferro Alloy Furna c es for extra c tion of m eta ls
from ores, w id ely know n a s Sub m erg ed Arc Furna c es. Our c ore c onc ep t is from inc ep tion
to R & D & to Develop ing a nd Ad a p ting tec hnolog ies w hic h a re ta ilerma d e a s p er
c usto m ers’ need s. Our d esig n inc orp ora tes the la test a nd p roven tec hnolog y w hic h a re
d evelop ed a nd im p lem ented b y us world over. We b elieve in p rovid ing tec hnolog ies a t
p a r w ith the interna tiona l sta nd a rd s for the use on world sc a le. Va ib ha v Furna c es
b elieves in c usto m er first a p p roa c h, rig ht tec hno lo g y to p ro c ess oriented d esig s resulting
in m inim izing unp rod uc tive d ela ys & lea d ing to op timum p rod uc tion. Rob ust d esig n is
the c ore ing red ient in our furna c es,w hic h m inim izes d ow n tim e in ma intena nc e. We a re
of the thoug ht tha t there should b e only sc hed uled ma intena nc e of the furna c es.
We ha ve Desig ned , sup p lied a nd c o m m issio ned o ur furna c es m eeting to string ent
q ua lity c ond itio ns . We a lso ensure tim ely d elivery of the p la nt eq uip m ents in ord er to
a void over run p rojec t c ost.
Introduction

Vaibhav Furnaces

 Ours is “A Young Company with Mature Brains”. We are engineering professionals, with
over twenty one years experience in Ferro Alloys and Steel plants. While initial years
started with working in Ferro alloys and Steel plants, we transformed our experience to
design the very equipments for which, we had worked initially.

 Our Design, Erection, Commissioning Stabilisation of plants began from 1992(from

multinational companies). Thus we are having eighteen years experience in design,
erection and commissioning.
• Our Strength - Design, erection, quality control, erection
(supervision), cold trial, hot trial, full fledged production of Ferro
alloys (complete) and steel plants (as per listed equipments).
• This we do on turn key basis
• As we do commissioning ourselves, we continuously improve our
design and incorporate all the view points (after proper analysis)
of experienced operators.
 Working philosophy:
 MECHANICAL
 We do the complete engineering of mechanical equipments with
3D software. With this software we achieve following :
 We check the complete assembly of the furnace. We check and
correct the interferences in the matching part.
 Design optimisation and finite elements determination.
 Optimum water requirement (on the basis of surface area
exposed to heat zone)
 We get the CG (centre of gravity) and accurate weight of the
equipment.
 Erection time is reduced drastically. In House Design Of Electrode
Holder in 3 D Software
 ELECTRICAL :

 We do the complete electrical engineering with latest software having capabilities of integrating all electrical
activities, single line diagram,bom, electrical symbols.This has got advantages over normal cad design.

 Fast, Easy & precise project configuration.

 Highest level of project documentation quality due to Standardization.

 Maximum Design flexibility. Panel Mounting, SLD

 Accurate & logical representation of all connected device through any bus topology, plc & single- line diagram.

 Eliminate error prone manual data entry of BOM, Interfacing, Assembly report.

 For the Arc furnace electrical design we do following calculations:

 Furnace impedance (based on the charge mix)

 Transformer voltage and impedance selection (on “K” value)

 Transformer voltage selection is done on the basis of types of Ferro alloys. The design incorporates PCD changing
provision and enhanced range of transformer voltages, if product change is envisaged.

 We incorporate arc furnace technology into submerged arc furnace. This helps the operator run the furnace in
controlled and easy way. Safety features, especially in Bellow type pressure rings and close/semi close roofs are
provided. This is based on the Arc furnaces technology.
Project control and monitoring:

• We prepare the complete project

planning with latest softwares. All
activities are based on our past
experience, meticulously recorded by
us in the previous projects
• This project planning is further
subdivided into detailed planning
area wise.
• This helps to meet the target dates,
very closely.
 Production line of SAF plant Designed by us

Raw Material In Yard Raw Material Transfer to Storage Weighing, Mixing & lifting charge
Hopper From Yard To Furnace Hopper

Charge feeding in Running Metal tapping from Furnace Braking & packing Finished Product
Furnace
Design Features Of SAF Of Vaibhav Furnaces
General Criteria
We Design the SAF to suit individual customer to
fit their requirement for specific process.

General SAF Design:

• Open
• Semi closed
• Closed
• Rotating

Furnace Gas Collecting Roof

• Round
• Close/ Semi Closed
• Top Water Cooled
• Air Curtain Fe-Alloy Plant During Erection
• Sliding Door
• Explosion door inside
panels (closed type Furnace) All Feature & design Available for customer
Fe-Alloy Plant During Erection Electrode Holder
Furnace Charging
•Manual Automatic
•Batch/ Continuous feeding
Furnace Shell
 Air Cooled
 Water Cooled
 Water Panel
 Stationary/ Rotating
 Flat Bottom
 Tilt able

Electrical Bus System

Bus tube/ Bus Bar
Water, Air Cooled Flexible
Cables Inside/ Out side Hood
Forged contact Clamp
Low impedance
Furnace Shell Cover/Roof
•Robust design
•Round/ Conical
•Water cooled
•Roof lining Bricks/Castable
Arcing at initial Start up
Fe-Si Furnace With Sliding Gate
Electrode Holder:
•Robust Electrode column
•Self Baking Sodurberg/ Pre-Baked
carbon electrode for Silicon metal
•Clamp position Below/Above
furnace roof
•Water cooling
•Cooling shield & protection ring
• smoke seals
•Lifting device
•Slipping device
•Controlled electrode regulation
Vaibhav Furnaces Special Design Features
Electrode Holder: This robust design of electrode holder give better result in
minimizing energy consumption, low maintenance & safe operation of
furnace. Hydraulic power pack

Main Components Of System

• Fail Safe hydraulic operated slipping & electrode regulation device.
• 1500 v Electrical Insulation
• Electrode casing welding in running furnace
• Controlled Electrode Slipping in full load
• Proper Electrode baking for current transfer

Electrodes : we Design Holder for pre-baked & self baked electrode Tap hole cooling

Self baking electrode : It reduce the production cost in Ferro alloy product
Fe-Si, Fe-Cr, CaC2.

Cooling & Refractory Lining Concept: We Design the cooling part &
refractory to ensure long life, safe operation & Minimum heat loss of
cooling equipment.
Electrical Aspects: high current electric component are Heart of Furnace & critical for energy
optimization and optimum production.

Vaibhav Furnaces design very carefully to minimize the power loss. We consider following during detail
engineering :
• Voltage & Impedance Of transformer
• Reactance Of High current Bus tube/ Bar
• Resistance Of charge
• “K” factor of the final products
• Proper insulation on live part
• Harmonic & PF correction
• Layout of Bus bar, to suit the impedence
• Proper selection of Electrode Diameter
• Insulations to minimize magnetizing effect

It Give Benefit to Customer

 Optimum Furnace operation High current Electric supply system
 Minimized electric losses
 Long life
Pollution Control System: We have vast experience in Arc Furnace Technologies, we
implements this to SAF for reducing pollution level to minimum with various concepts for
stringent condition So it gives Environmentally friendly condition.

Main System:

• Spark Arrestor Various design Available

Off Gas Temperature control by using
Various type Heat exchanger
• Wet Scrubber
Furnace running with Zero pollution
• Dry Scrubber Cyclone & filter station Kuwait
In stringent condition in Kuwait
• On line/ off line pulsing

Customer benefit
Environmentally Responsible system
& Multiple choice for selection various
System As per requirement

HYDRAULIC PIPING
Installation: Advantage With Vaibhav Furnaces

• Experienced Team for procurement/ • Optimum electrical energy

planning, erection & commissioning • Optimum manpower
• Strong back ground In Design & erection • Quality improvement
• Cost reduction
• Installations for which engineering done by • Best technology with flexibility for
us) : automation
• Complete Ferro alloy plant with gas • Less down time
cleaning and material handling system
• Arc Furnaces
• Ladle Furnaces
• Vacuum degassing (VD) and Vacuum oxygen
decarburization.
• Fume Treatment plant
• Auxiliaries
• Consultancy from concept to
commissioning.

Two 7 MVA Furnace For 78-80% Fe-Si

Our Mission

 Our Company designs robust, maintenance free STATE- OF-THE ART Submerged Arc
Furnaces for Reliability, Consistency & Quality Product with Optimum Production with
Optimum Electric Power & Manpower.

 Design, Erection & Commissioning of Submerged Arc Furnace, Complete Plant for
Producing highest quality product as per end users requirements.

 We designed Plant for Environmentally friendly operation for stringent condition.

After completion of project we closely monitor it’s operation & take feed backs from
customers time to time & help them for achieving optimum target & reducing production
cost.

Our Vision :
 Our aim is to develop core engineering of the complete plant with the latest designs
and soft wares. This would help us in providing engineering at part with the European
competitors with Indian Price.
Our website : www.vaibhavfurnaces.com

Get In Touch :-

• Mailing Address .
• Vaibhavfurnaces@yahoo.com
• vaibhavfurnaces@yahoo.com
• vaibhavfurnaces@gmail.com
• vipin@vaibhavfurnaces.com

Mobile Nos :

 08004275098
(Vipin Gupta, CEO)
 07828747543
(Manoj Gupta, Director - Finance)