Comprehensive Analysis for Modernization of 100 t Electric Arc Furnace for Steel Production (original) (raw)

Aspects of the electric arc furnace control

Operating mode of electric arc furnace is influenced by a series of disturbances. These perturbations lead to growth of specific energy consumption and decrease in total electric oven We addressed the mathematical modeling of electric arc furnace (EAF) by analysis of related technological processes and the possibility of using simulation software model arc furnace as part of the grid. Mathematical modeling of electric arc furnace related processes (EAF) in order to optimize functional and technological performance of this complex aggregate has the direct positive consequences reducing specific consumption of electricity in steel development with about 15%, simultaneously obtaining a high quality steels electricity produced.

Improvement of electrical arc furnace operation with an appropriate model

Energy, 2009

Electrical arc furnaces are commonly employed in industry to produce molten steel by melting iron and scrap steel. Furnace control is a necessary operation for production optimization. The principal parameters to be controlled are: maximum productivity requirements, minimum power off time, good power quality and safety. The aim of this study is to achieve all these objectives. Hence, because of the stochastic and dynamic behaviour of the arc during the melting process, a proposed model is checked with measurements at an industrial electrical arc furnace. How electrodes position and transformer taps can affect X and R arc function are discussed in detail. This new operating strategy has been determined taking into account Flicker, melting stages and electrode positions. It is shown that optimum efficiency can be reached by the integration of the proposed model in regulation loop.

Optimization of electric arc furnace process at Deutsche Edelstahlwerke

Archives of Metallurgy and Materials, 2008

During stainless steel production in the electric arc furnace (EAF), oxygen is injected to oxidize unwanted tramp elements, mainly carbon and silicon. Unfortunately, oxygen also oxidizes precious elements such as iron and chromium which causes economical loss and bad environmental impact. Off-gas analysis was performed at Deutsche Edelstahlwerke (DEW) to control the decarburization so that the elements, not only carbon, oxidation and oxygen consumption can be controlled as well. This paper presents a new strategy to control the elements oxidation as well as to increase the oxygen efficiency. For the investigated heat, the well controlled decarburization will decrease the oxygen consumption by about 10%. Work was carried out with a financial grant from the Research Fund for Coal and Steel of the European Community.

Theoretical Estimation of Peak Arc Power to Increase Energy Efficiency in Electric Arc Furnaces

ISIJ International, 2013

This research work introduces the concept of "useful arc power" and the thermal model, first introduced by Dittmer and Krüger, to establish the arc length at any stage of the heat in Alternate Current Electric Arc Furnaces (AC-EAF), based on the estimation of the fraction of the energy transferred to the metallic load by radiation. Radiation is the most effective way to transfer heat in an arc furnace in presence of metallic scrap (bore-in and early meltdown). On the other hand, if the arc is not adequately covered with slag, radiation is extremely dangerous to the furnace integrity. When the furnace is fully loaded, scrap protects the walls and cooling panels and then arc radiation must be maximized. To increase energy efficiency, and at the same time reduce circuit power losses, the arc length should be controlled. However, arc instability prevents to increase radiation, as desired, and a compromise must be reached between arc length and arc stability. In this work AC-EAF electric circuit is modeled and analyzed under different heat stages. Electrodes, anode and cathode, fall regions can be considered as energy losses and their associated power may be deducted for the estimation of the "useful arc power" and for the definition of the operational currents in the heat process, particularly during flat bath conditions (late meltdown and refining). As a result of the present study it is proved that current setpoints play an important role for energy saving at any stage of the heat. Finally, experimental results obtained from an industrial steel factory validate this approach to optimize the electrical energy consumption per ton of liquid steel in AC-EAF.

Effect of Heat Loss on the Working Index of Electric Arc Furnace (EAF)

Borobudur Engineering Review, 2023

Day in day out of human life the use of metal is inevitable, metals are needed for different purposes such as in construction of bridges houses, roads etc. But despite the availability of huge amount of metal, it does not meet the global demand thus this paper investigate the effect of reduction of power of heat loss on the cost of production of electric arc furnace. In order to achieve maximum precision during production, getting product at relatively reduced price has remained a major challenge to the scientists. The experiment was conducted at industrial scale whereby power of heat loss was varied from 7.707-4.624 MW while energy consumption fell from 0.5463 to 0.5317 MW-Hour per ton and productivity tremendously increased from 253.0 ton to 254.0 ton per hour. Data used were collected from active furnace in Zerepaves Metallurgical plant, Russia and further analyzed with software package for accuracy.

Exergy and energy analysis of an AC steel electric arc furnace under actual conditions

International Journal of Exergy, 2013

The energy and exergy analyses of an existing steel Electric Arc Furnace (EAF) are performed to estimate the potential for increasing the furnace efficiency. To obtain realistic results, the effect of air infiltration into the furnace was taken into account. The results of the analyses revealed that the energy and exergy efficiencies of the furnace are low and should be increased. The main sources of energy waste are stack gases followed by heat transfer to the cooling water, while the main sources of exergy destruction are combustion and heat transfer. Hot stack gases contain 18.3% and 12.2% of the total input energy and exergy, respectively. Increasing the air infiltration reduces the energy and exergy efficiencies of the EAF. By using the energy of flue gas to preheat the sponge iron, the electrical energy consumption of the furnace can be reduced by 89 GJ, dictating a 21.4% reduction in electrical energy consumption and a 13.6% increase in steel production.

Modeling and Experimental Analysis for Modernization of 100-t EAF

IEEE Transactions on Industry Applications, 2010

This paper presents an experimental investigation and modeling solutions of an electric arc furnace (EAF) with 100-t capacity used for steel melting in order to evaluate the best option for improvement. Experimental results show that EAFs represent a substantial source of electric disturbances such as voltage fluctuations, flicker, harmonics, and imbalance between phases. Improvement of the energetic performances of an EAF imposes a careful technical and economical analysis. The static voltampere reactive compensator solution is the best one for compensating the reactive energy and increasing the power factor but has the highest costs. Also, we evaluate existing processes' equipment performance, the point of improvement opportunities for the best operating efficiency. Substantial reductions in the energy consumption and in the defects of mechanical nature are obtained by the proposed automation solution of the auxiliary installations.

Heat balance analysis in electric arc furnace for process improvement

E3S Web of Conferences

The current study deals with optimizing the melting process used in electric arc furnace by heat balance equations. Heat balance is a very important aspect in an arc furnace in which the energy input consists of electrical energy [65%], chemical energy [25%] and exothermic reaction heat [10%]. This energy is optimized with the charge mix, charge quantity, fluxes, fuel used, and O2 used in the burners. The present model considers all these aspects and gives heat distribution in the process. The model spreadsheet gives a reasonable prediction in terms of metal yield, composition, and energy consumption. The model also predicts the amount of iron oxidized in the process. The mass and heat balance model is a useful tool for process analysis and improves the process efficiency of electric arc furnace steelmaking.

Experimental analysis of electric parameters of a 100 t UHP electric arc furnace

2010 IEEE International Conference on Industrial Technology, 2010

This paper presents a study of power quality problems created by a UHP electric arc furnace (EAF) operation at power system. We are analyzing an electric arc furnace of 100 t capacity used for steel melting, and the related steel treatment installation. The measurements have been made using the CA8334 three-phase power quality analyser. Experimental results show that the EAF are a substantial source of electric disturbances, such as voltage fluctuations, flicker, harmonics, and unbalance between phases. Improvement of the energetic performances of an electric arc furnace imposes a careful technical and economical analysis, for choosing the possible solutions for balancing the load on phases, improving the wave forms (current and voltage) and improving the power factor.

IJERT-Power Quality Improvement in Electric Arc Furnace

International Journal of Engineering Research and Technology (IJERT), 2015

https://www.ijert.org/power-quality-improvement-in-electric-arc-furnace https://www.ijert.org/research/power-quality-improvement-in-electric-arc-furnace-IJERTV4IS040198.pdf Electric arc furnaces (EAFs) are the worst offending loads which pollutes the power quality. But AC arc furnace is a industrial load having variation with respect to time and is nonlinear which can cause many problems to the power system quality, including voltage dips, harmonic distortion, unbalance loads and flicker. Electric Arc Furnaces are used in steel plants for producing high quality steel. Modelling of the electric arc furnace with all its features is accomplished using a technique developed based on CAVIAR Software. It is demonstrated in this paper that SVC gives the best performance of all possible solutions. The design aspects of SVC and Filters for the EAF to improve the voltage profile of the system at the point of common coupling are discussed in this paper.