Abstract
A dynamic, first-principles process model for a steelmaking electric arc furnace has been developed. The model is an integrated part of an application designed for optimization during operation of the furnace. Special care has been taken to ensure that the non-linear model is robust and accurate enough for real-time optimization. The model is formulated in terms of state variables and ordinary differential equations and is adapted to process data using recursive parameter estimation. Compared to other models available in the literature, a focus of this model is to integrate auxiliary process data in order to best predict energy efficiency and heat transfer limitations in the furnace. Model predictions are in reasonable agreement with steel temperature and weight measurements. Simulations indicate that industrial deployment of Model Predictive Control applications derived from this process model can result in electrical energy consumption savings of 1–2%.
Highlights
Electrical arc furnaces (EAF) perform a primary steelmaking process that converts recycled steel scrap into liquid steel, which can be refined further in downstream processes
During the course of a heat, the burners can operate in two different modes: (1) by providing pure oxygen for refining, or (2) by providing a mixture of oxygen and either liquefied natural gas (LNG) or propane to burn for extra heating
The inner solid mass is heated directly by the electric arc and always begins to melt first, while the outer solid mass begins to melt before the inner solid is completely liquefied
Summary
Electrical arc furnaces (EAF) perform a primary steelmaking process that converts recycled steel scrap into liquid steel, which can be refined further in downstream processes. Gas burners are mounted along the outer vessel sidewalls. During the course of a heat, the burners can operate in two different modes: (1) by providing pure oxygen for refining, or (2) by providing a mixture of oxygen and either liquefied natural gas (LNG) or propane to burn for extra heating. The burners are typically operated in fuel combustion mode during the early process stages, while refining takes place towards the end of the heat. To protect the vessel and furnace equipment from sustaining damage due to radiation from the electric arc and heated metal, cooling water heat exchange panels are mounted along the upper parts of the vessel’s sidewalls and the roof [1]
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