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Physics-Based Modeling of Electric Operation, Heat Transfer, and Scrap Melting in an AC Electric Arc Furnace

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Abstract

Electric arc furnaces (EAF) are complex industrial plants whose actual behavior depends upon numerous factors. Due to its energy intensive operation, the EAF process has always been subject to optimization efforts. For these reasons, several models have been proposed in literature to analyze and predict different modes of operation. Most of these models focused on the processes inside the vessel itself. The present paper introduces a dynamic, physics-based model of a complete EAF plant which consists of the four subsystems vessel, electric system, electrode regulation, and off-gas system. Furthermore the solid phase is not treated to be homogenous but a simple spatial discretization is employed. Hence it is possible to simulate the energy input by electric arcs and fossil fuel burners depending on the state of the melting progress. The model is implemented in object-oriented, equation-based language Modelica. The simulation results are compared to literature data.

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Abbreviations

Re:

Reynolds number

Pr:

Prandtl number

Nu:

Nusselt number

ε :

Porosity

η :

Efficiency

ρ :

Density (kg m−3)

A :

Area (m2)

b :

Fitting factor for stack effect

c p , c v :

Specific heat capacity (J kg−1 K−1)

d, D :

Diameter (m)

E a :

Voltage drop (V mm−1)

f a :

Packing factor

g :

Acceleration due to gravity (m s−2)

h :

Specific enthalpy (J kg−1)

h :

Coefficient of heat transfer (W m−2 K−1)

h fusion :

Heat of fusion (J kg−1)

H :

Height (m)

Hi :

Lower heating value (J kg−1)

I :

Current (A)

I, J, K :

Number of elements in φ, r, z direction

k :

Minor pressure loss coefficient

m :

Mass (kg)

\( \dot{m} \) :

Mass flow rate (kg s−1)

φ, r, z :

Coordinates of solid-phase discretization

P :

Effective power (W)

P C :

Copper losses (W)

\( \dot{Q} \) :

Heat flow rate (W)

r :

Radius (m)

R :

Resistance (Ω)

s :

Distance (m)

S :

Apparent power (VA)

t :

Time (s)

T :

Temperature (K)

u sc :

Relative short-circuit voltage (pct)

U :

Voltage (V)

U an :

Anode drop (V)

V :

Volume (m3)

\( \dot{V} \) :

Volume flow rate (kg m−3)

w :

Velocity (m s−1)

x :

Share

X :

Reactance (Ω)

Y :

Admittance (Ω−1)

\( \underline{Z} \) :

Complex variables

0:

Reference value

a:

Arc

amb:

Ambient

b:

Burner

bb:

Busbar

bl:

Blower

cr:

Controlled reactance

e:

Solid element

eaft:

Furnace transformer

el:

Electrode

f:

Furnace

fe:

Furnace equipment

fc:

Filter capacitor

fr:

Flow resistance

g:

Gas phase

hc:

High-current system

l:

Liquid phase

lf:

Ladle furnace

liq:

Quantity at liquidus point

r:

Rated

rea:

Reactor

s:

Solid phase

sdt:

Step-down transformer

sol:

Quantity at solidus point

v:

Vessel

w:

Wall

CFD:

Computational fluid dynamics

lam:

Laminar

PCC:

Point of common coupling

SVC:

Static VAR compensation

turb:

Turbulent

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Acknowledgments

This research project is funded by the German Federal Ministry of Education and Research (BMBF) within the framework concept ‘IngenieurNachwuchs’ (Fund Number 03FH00212).

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Authors and Affiliations

  1. Offenburg University of Applied Sciences, Badstr. 24, 77652, Offenburg, Germany

    Florian Opitz (Scientific Assistant) & Peter Treffinger (Professor)

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  1. Florian Opitz
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  2. Peter Treffinger
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Correspondence to Florian Opitz.

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Manuscript submitted October 5, 2015

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Opitz, F., Treffinger, P. Physics-Based Modeling of Electric Operation, Heat Transfer, and Scrap Melting in an AC Electric Arc Furnace. Metall Mater Trans B 47, 1489–1503 (2016). https://doi.org/10.1007/s11663-015-0573-x

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