Improved Modeling and Optimal Control of an Electric Arc Furnace
Improved Modeling and Optimal Control of an Electric Arc Furnace

Author: Jared James Snell

Publisher:

Published: 2010

Total Pages: 146

ISBN-13:

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This thesis centers around an electric arc furnace (EAF) at a steel mini-mill in Wilton, IA. First, the thesis replicates previous optimization attempts. Next, the modeling is greatly altered to produce a much improved steel-melting model. Then, a new optimal control system is created and used to reduce energy and fuel costs over the melting process. Finally, results are presented. This thesis shows that when the new optimal control is simulated, the system shows significant energy and fuel savings.

Masters Theses in the Pure and Applied Sciences
Masters Theses in the Pure and Applied Sciences

Author: W. H. Shafer

Publisher: Springer Science & Business Media

Published: 2013-03-14

Total Pages: 307

ISBN-13: 1475757859

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Masters Theses in the Pure and Applied Sciences was first conceived, published, and dis seminated by the Center for Information and Numerical Data Analysis and Synthesis (CINDAS) * at Purdue University in 1957, starting its coverage of theses with the academic year 1955. Beginning with Volume 13, the printing and dissemination phases of the ac tivity were transferred to University Microfilms/Xerox of Ann Arbor, Michigan, with the thought that such an arrangement would be more beneficial to the academic and general scientific and technical community. After five years of this joint undertaking we had concluded that it was in the interest of all concerned if the printing and distribution of the volume were handled by an international publishing house to assure improved service and broader dissemination. Hence, starting with Volume 18, Masters Theses in the Pure and Applied Sciences has been disseminated on a worldwide basis by Plenum Publishing Corporation of New York, and in the same year the coverage was broadened to include Canadian universities. All back issues can also be ordered from Plenum. We have reported in Volume 24 (thesis year 1979) a total of 10,033 theses titles from 26 Canadian and 215 United States universities. We are sure that this broader base for theses titles reported will greatly enhance the value of this important annual reference work. While Volume 24 reports these submitted in 1979, on occasion, certain universities do report theses submitted in previous years but not reported at the time.

Modeling, Optimization and Estimation in Electric Arc Furnace (EAF) Operation
Modeling, Optimization and Estimation in Electric Arc Furnace (EAF) Operation

Author: Yasser Emad Moustafa Ghobara

Publisher:

Published: 2013

Total Pages: 186

ISBN-13:

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The electric arc furnace (EAF) is a highly energy intensive process used to convert scrap metal into molten steel. The aim of this research is to develop a dynamic model of an industrial EAF process, and investigate its application for optimal EAF operation. This work has three main contributions; the first contribution is developing a model largely based on MacRosty and Swartz (2005) to meet the operation of a new industrial partner (ArcelorMittal Contrecoeur Ouest, Quebec, Canada). The second contribution is carrying out sensitivity analyses to investigate the effect of the scrap components on the EAF process. Finally, the third contribution includes the development of a constrained multi-rate extended Kalman filter (EKF) to infer the states of the system from the measurements provided by the plant. A multi-zone model is developed and discussed in detail. Heat and mass transfer relationships are considered. Chemical equilibrium is assumed in two of the zones and calculated through the minimization of the Gibbs free energy. The most sensitive parameters are identified and estimated using plant measurements. The model is then validated against plant data and has shown a reasonable level of accuracy. Local differential sensitivity analysis is performed to investigate the effect of scrap components on the EAF operation. Iron was found to have the greatest effect amongst the components present. Then, the optimal operation of the furnace is determined through economic optimization. In this case, the trade-off between electrical and chemical energy is determined in order to maximize the profit. Different scenarios are considered that include price variation in electricity, methane and oxygen. A constrained multi-rate EKF is implemented in order to estimate the states of the system using plant measurements. The EKF showed high performance in tracking the true states of the process, even in the presence of a parametric plant-model mismatch.

Simulation and Optimization of Furnaces and Kilns for Nonferrous Metallurgical Engineering
Simulation and Optimization of Furnaces and Kilns for Nonferrous Metallurgical Engineering

Author: Chi Mei

Publisher: Springer Science & Business Media

Published: 2010-12-28

Total Pages: 351

ISBN-13: 364200248X

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"Simulation and Optimization of Furnaces and Kilns for Nonferrous Metallurgical Engineering" is based on advanced theories and research methods for fluid flow, mass and heat transfer, and fuel combustion. It introduces a hologram simulation and optimization methods for fluid field, temperature field, concentration field, and electro-magnetic field in various kinds of furnaces and kilns. Practical examples and a detailed introduction to methods for simulation and optimization of complex systems are included as well. These new methods have brought significant economic benefits to the industries involved. The book is intended for researchers and technical experts in metallurgical engineering, materials engineering, power and thermal energy engineering, chemical engineering, and mechanical engineering. Chi Mei, Jiemin Zhou, Xiaoqi Peng, Naijun Zhou and Ping Zhou are all professors at School of Energy Science and Engineering, Central South University, Changsha, Hunan Province, China.

Determining Process Conditions for Online Monitoring of Temperature and Carbon Content in the Electric Arc Furnace to Optimize End Point Control (MELTCON)
Determining Process Conditions for Online Monitoring of Temperature and Carbon Content in the Electric Arc Furnace to Optimize End Point Control (MELTCON)

Author:

Publisher:

Published: 2017

Total Pages:

ISBN-13: 9789279771903

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Due to the high heating power of the electric arc furnace, precise end point control of the EAF refining process is essential for efficient melt processing. The evolution of the steel bath temperature was measured during the EAF refining phase using a novel fibre optical measurement system based on the DynKonTemp® technique developed by BFI. This measurement system was applied at the high productivity furnace of Ferriere Nord producing construction steels and the furnace of Saarschmiede Freiformschmiede producing high quality forging steel grades. Fibre optical online measurement of the carbon content in the melt failed due to the low signal to background relation of the thermal excited transition. The continuous liquid steel temperature measurements were also used to optimize the performance of dynamic EAF process models. The dynamic process models for melt temperature and carbon content were validated by conventional thermocouple measurements and chemical analysis of steel samples. In addition, to interpret the measurement results, the processes of both steel shops were simulated using computational fluid dynamics calculations. Fluid flow and distribution of steel bath temperature and carbon content were modelled to determine optimal measurement time, minimum measurement duration, and influence of the measurement position. Based on the analysis of the liquid steel temperature evolution, more reliable set points for energy input and temperature control are determined. Thus, the combined use of offline CFD calculations, online dynamic process modelling, and fibre optical inline measurement leads to enhanced EAF end point control.

Electric Arc Furnace: Methods to Decrease Energy Consumption
Electric Arc Furnace: Methods to Decrease Energy Consumption

Author: Alberto N. Conejo

Publisher: Springer

Published: 2024-11-09

Total Pages: 0

ISBN-13: 9789819740529

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The Electric Arc Furnace (EAF) will become the largest producer of steel worldwide, replacing the conventional route through the blast furnace and BOF. In most developed countries the EAF process is already the main steelmaking reactor. This is due to many advantages, such as much lower emissions of CO2, higher flexibility in furnace capacity and higher flexibility in the raw materials such as scrap, direct reduced iron (DRI) and pig iron. The EAF process has also experienced a larger level of automation that provides a higher productivity. However, the EAF process also has a large number of limitations in comparison with the BOF, for example; (i) use of an expensive type of energy (electric energy), (2) very poor stirring conditions which results in lower decarburization rates, (3) residual elements in steel scrap, (3) cost of scrap can be higher than iron ore, (4) dependance on DRI to produce higher quality steels, (5) higher heat losses, (6) lower metallic yield (slag leaves the furnace losing iron and heat). If the EAF process overcomes these limitations it will be able to fully overcome the BF-BOF route and become the dominant process for steelmaking in the 21st century. This book discusses in detail 15 methods to decrease energy consumption in the EAF. Decreasing energy consumption requires an integral approach which means that all methods should be fully understood and optimized.