Abstract: An electric arc furnace having a partially insulated electrode produces molten metal such as foundry iron from an iron source where little or no slag is produced. The furnace includes at least one insulated electrode assembly for immersing deep into the metal charge. The electrode assembly has an electrically conducting member coupled to an electrode. The electrode has a coupling member at the upper end for coupling with the electrically conducting member and a coupling member at the lower end for coupling with an adjacent electrode to form an electrode column. The coupling members can be an internally threaded recess in the ends thereof. An externally threaded coupling member can be threaded into the recesses of the electrodes for coupling two or more electrodes together.

Abstract: A submerged arc furnace having a partially insulated electrode produces molten metal such as foundry iron from scrap iron and steel sources where little or no slag is produced. The metal source, scrap iron or steel is fed into the submerged arc furnace with a source of silica and a carbonaceous reducing agent. The scrap iron and steel is melted while simultaneously smelting the silica in the presence of the carbonaceous reducing agent. The insulation surrounding the electrode can be a silica containing material, such as fiberglass, which is reduced to provide silicon to the molten metal. The amount of the silica source and carbonaceous reducing agent are added in an amount to selectively control the silicon and carbon content of the resulting foundry iron.

Abstract: A submerged arc furnace produces foundry iron from scrap iron and steel sources where little or no slag is produced. Scrap iron or steel is fed into the submerged arc furnace with a source of silica and a carbonaceous reducing agent. The scrap iron and steel is melted while simultaneously smelting the silica in the presence of the carbonaceous reducing agent. The amount of the silica source and carbonaceous reducing agent are added in an amount to selectively control the silicon and carbon content of the resulting foundry iron.