SIMETALCIS EAF Optimization    Dynamic process optimization for Electric Arc Furnace

The Electric Arc Furnace (EAF) process optimization system is a completely integrated solution to operate the aggregate at an extremely high efficiency and availability to produce the required quantities. The solution is particularly suitable for a wide range of steel grades, including carbon steels, stainless steels and special steels while accommodating variable charging ratios of scrap, DRI (Direct Reduced Iron) and hot metal.

EAF operator pulpit The challenge While demands on products and processes are ever increasing, steel producers meet capacity limits that may not least be caused by inadequate automation technology. Often, outdated automation systems supply poor optimization and insufficient documentation of steelmaking processes and thus cause high maintenance costs. Steel bath temperature control is one of the main important issues of EAF steel production. Direct continuous measurements of steel properties are currently not possible and the measurement of steel temperature and composition interrupts the treatment process, thereby increasing tap-to-tap-time. Standard melting profiles can only take the target steel quality into account. The actual course of the melting and refining process (e.g. actual charged materials, actual blown oxygen/carbon) which strongly influences the condition of the steel bath cannot be considered.

Our solution

Siemens VAI automation systems are based on decades of combined engineering, plant-building, operational, metallurgical and automation experience and are the key to high-profit EAF steelmaking. Siemens VAI is able to provide stable automation systems due to the application of their well-proven solutions. In addition, both integrated and standalone automation solutions are provided for all levels. The dynamic EAF process models, which are purely based on physical and chemical principles, make it possible to achieve accurate imaging of the complete melting and refining process. The advanced process models determine – in a cost optimizing way - the required charging and alloying materials and enable a full automatic control of the EAF process. The prediction model performs a precalculation of the complete heat before actual treatment. It gives a preview of the melting process and steel condition at tapping and allows adjustment of the standard melting practice. In case of continuous material feeding (e.g. DRI) the optimum feeding rate targeting at constant steel temperature is dynamically determined. The EAF process models allow for offline tuning and simulation prior to release to the production system. Unlike other solutions, no software modifications are necessary to adapt model behavior. To round off the package, Siemens VAI provides worldwide metallurgical and automation assistance via remote links and local Siemens VAI service representatives.

Good reasons for SIMETALCIS EAF Optimization

Reduction of tap-to-tap time

Reduction of energy consumption

Reduction of alloying material costs

Standardized production operation for constantly high quality

Full functionality provided at start-up