Modelling of electric energy consumption in the AC electric arc furnace

The electric arc furnace operation at the Štore Steel company, one of the largest flat spring steel producers in Europe, consists of charging, melting, refining the chemical composition, adjusting the temperature, and tapping. Knowledge of the consumed energy within the individual electric arc operation steps is essential. The electric energy consumption during melting and refining was analyzed including the maintenance and technological delays. In modeling the electric energy consumption, 25 parameters were considered during melting (e.g., coke, dolomite, quantity), refining and tapping (e.g., injected oxygen, carbon, and limestone quantity) that were selected from 3248 consecutively produced batches in 2018. Two approaches were employed for the data analysis: linear regression and genetic programming model. The linear regression model was used in the first randomly generated generations of each of the 100 independent developed civilizations. More accurate models were subsequently obtained during the simulated evolution. The average relative deviation of the linear regression and the genetic programming model predictions from the experimental data were 3.60% and 3.31%, respectively. Both models were subsequently validated by using data from 278 batches produced in 2019, where the maintenance and the technological delays were below 20 minutes per batch. It was possible, based on the linear regression and the genetically developed model, to calculate that the average electric energy consumption could be reduced by up to 1.04% and 1.16%, respectively, in the case of maintenance and other technological delays.

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Modeling the Effect of Scrap on the Electrical Energy Consumption of an Electric Arc Furnace

Processes ◽

10.3390/pr8091044 ◽

2020 ◽

Vol 8 (9) ◽

pp. 1044

Author(s):

Leo S. Carlsson ◽

Peter B. Samuelsson ◽

Pär G. Jönsson

Keyword(s):

Energy Consumption ◽

Statistical Model ◽

Electrical Energy ◽

Electric Arc Furnace ◽

Electric Arc ◽

Melting Time ◽

Arc Furnace ◽

Total Energy Consumption ◽

Data Set ◽

Practical Usefulness

The melting time of scrap is a factor that affects the Electrical Energy (EE) consumption of the Electric Arc Furnace (EAF) process. The EE consumption itself stands for most of the total energy consumption during the process. Three distinct representations of scrap, based partly on the apparent density and shape of scrap, were created to investigate the effect of scrap on the accuracy of a statistical model predicting the EE consumption of an EAF. Shapley Additive Explanations (SHAP) was used as a tool to investigate the effects by each scrap category on each prediction of a selected model. The scrap representation based on the shape of scrap consistently resulted in the best performing models while all models using any of the scrap representations performed better than the ones without any scrap representation. These results were consistent for all four distinct and separately used cleaning strategies on the data set governing the models. In addition, some of the main scrap categories contributed to the model prediction of EE in accordance with the expectations and experience of the plant engineers. The results provide significant evidence that a well-chosen scrap categorization is important to improve a statistical model predicting the EE and that experience on the specific EAF under study is essential to evaluate the practical usefulness of the model.

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Exergy Analysis of Steel Electric Arc Furnace

ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis, Volume 1 ◽

10.1115/esda2010-24239 ◽

2010 ◽

Author(s):

Ebrahim Hajidavalloo ◽

Hamzeh Dashti

Keyword(s):

Energy Consumption ◽

Flue Gas ◽

Exergy Analysis ◽

Steel Production ◽

Electrical Energy ◽

Electric Arc Furnace ◽

Electric Arc ◽

Arc Furnace ◽

Electrical Energy Consumption ◽

Energy And Exergy

In this paper, energy and exergy analysis of an existing steel electric arc furnace (EAF) was performed to estimate the furnace potential for increasing the efficiency and decreasing the electrical energy consumption. The results of analysis show that the energy and exergy efficiencies of the furnace are 56.9% and 40.5%, respectively. Field data show that mass flow rate of hot flue gas is around 10.4 kg/s in average which contains 18.3% and 12.2% of total input energy and exergy, respectively. By using energy of flue gas for preheating the sponge iron, electrical energy consumption of the furnace could be reduced up to 88 GJ which means 21.2% reduction in electrical energy consumption and 13.6% increase in steel production. Also, exergy efficiency improves about 10.8% by using preheating scheme.

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Process Analysis of the Electric Arc Furnace Melting for Alumina Spinel Production

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.602-604.2104 ◽

2012 ◽

Vol 602-604 ◽

pp. 2104-2107

Author(s):

Guo Chao Qi ◽

Feng Jun Shan ◽

Qiang Li ◽

Jing Yuan Yu

Keyword(s):

Electric Power ◽

Power Efficiency ◽

Process Analysis ◽

Electric Energy ◽

Power Input ◽

Electric Arc Furnace ◽

Electric Arc ◽

Arc Furnace ◽

High Quality ◽

Furnace Melting

Alumina spinel is widely used as a refractory material in metallurgy industries. Arc furnace melting method is suitable to produce high quality alumina spinel. However, the high melting temperature (> 2200 °C) and high electric energy consumption limit the application of this method. There exists huge opportunity for energy saving through process optimization. A newly designed 2400 kVA electric arc furnace is used as melting facility to produce alumina spinal in this study. It shows from the experiments and analysis that melting voltage has much effect on electric power input and electric efficiency. At voltages higher than 150V, stable electric power input and adequate efficiency can be maintained. Stable melting voltage is difficult to maintain at 100-150V range and power efficiency are also apparently lower. For voltage less than100V, the process is very difficult to control and energy efficiency are very poor. Too high voltage on the other hand can lead the electric arc expose directly to the surroundings and increase the energy loss. In practical melting process, controlling the melting voltage at 140-160V range is suitable for high quality alumina spinel production.

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Thermodynamic analysis of solid waste and energy consumption to reduce the effects of an electric arc furnace on the environment

International Journal of Global Warming ◽

10.1504/ijgw.2019.103725 ◽

2019 ◽

Vol 19 (3) ◽

pp. 308 ◽

Cited By ~ 1

Author(s):

Yildiz Koc ◽

Huseyin Yagli ◽

Enver Onur Ozdes ◽

Ertugrul Baltacioglu ◽

Ali Koc

Keyword(s):

Energy Consumption ◽

Solid Waste ◽

Thermodynamic Analysis ◽

Electric Arc Furnace ◽

Electric Arc ◽

Arc Furnace

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Modelling of electrical energy consumption in an electric arc furnace using artificial neural networks

Energy ◽

10.1016/j.energy.2015.07.068 ◽

2016 ◽

Vol 108 ◽

pp. 132-139 ◽

Cited By ~ 37

Author(s):

Dragoljub Gajic ◽

Ivana Savic-Gajic ◽

Ivan Savic ◽

Olga Georgieva ◽

Stefano Di Gennaro

Keyword(s):

Neural Networks ◽

Artificial Neural Networks ◽

Energy Consumption ◽

Electrical Energy ◽

Electric Arc Furnace ◽

Electric Arc ◽

Arc Furnace ◽

Electrical Energy Consumption ◽

Artificial Neural

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Coke and coal as reductants in manganese ore smelting: An experiment

Mineralogia ◽

10.2478/mipo-2018-0004 ◽

2018 ◽

Vol 49 (1-4) ◽

pp. 35-45 ◽

Cited By ~ 1

Author(s):

Bambang Suharno ◽

Fajar Nurjaman ◽

Achmad Rifki ◽

Robby Krisnaldo Elvin ◽

Alif Ardiansyah Putra ◽

...

Keyword(s):

Energy Consumption ◽

Specific Energy ◽

Bituminous Coal ◽

Specific Energy Consumption ◽

Electric Arc Furnace ◽

Electric Arc ◽

Manganese Ore ◽

Arc Furnace ◽

X Ray ◽

Kg Medium

Abstract The effect of coke and bituminous coal on the reduction of medium-grade manganese ore in ferromanganese production was investigated. Charges of 30 kg medium grade manganese ore, 12 kg limestone and varied amounts of coke and coal were smelted in a Submerged Electric Arc Furnace (SAF) at temperatures of 1300°C to 1500°C. The composition of the ferromanganese and the slag were determined by X-Ray Fluorescence. It was found that using coke as a single reductant resulted in a 96% yield of ferromanganese which was higher than by using coal either as a single reductant or in a mixture of coal and coke. It was also found that using coke as a single reductant resulted in the lowest specific energy consumption. Using coal as reductant produced ferromanganese containing high sulfur and phosphorus.

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Improvement of Energy Efficiency and Productivity in an Electric Arc Furnace through the Modification of Side-Wall Injector Systems

Processes ◽

10.3390/pr8101202 ◽

2020 ◽

Vol 8 (10) ◽

pp. 1202

Author(s):

Yonmo Sung ◽

Sangyoun Lee ◽

Kyungmoon Han ◽

Jaduck Koo ◽

Seongjae Lee ◽

...

Keyword(s):

Energy Consumption ◽

Energy Cost ◽

Side Wall ◽

Cost Savings ◽

Electrical Energy ◽

Electric Arc Furnace ◽

Electric Arc ◽

Arc Furnace ◽

Electrical Energy Consumption ◽

Efficiency And Productivity

The energy cost of producing steel in an electric arc furnace (EAF) has a sizable influence on the prices of natural gas and electricity. Therefore, it is important to use these energies efficiently via a tailored oxy-fuel combustion burner and oxygen lance. In this study, an important modification of the side-wall injector system in the EAF at Hyundai Steel Incheon works was implemented to reduce electrical energy consumption and improve productivity. A protruding water-cooled copper jacket, including a newly designed burner, was developed to reduce the distance between the jet nozzle and the molten steel. In addition, the jet angles for the burner and lance were separately set for each scrap melting and refining mode. The modifications led to a reduction in electrical energy consumption of 5 kWh/t and an increase in productivity of approximately 3.1 t/h. Consequently, total energy cost savings of 0.3 USD/t and a corresponding annual cost savings of approximately 224,000 USD/year were achieved.

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