Model-Based Decision Support System for Electric Arc Furnace (EAF) Online Monitoring and Control

In this work, a practical approach for a decision support system for the electric arc furnace (EAF) is presented, with real-time heat state monitoring and control set-point optimization, which has been developed within the EU-funded project REVaMP and applied at the EAF of Sidenor in Basauri, Spain. The system consists of a dynamic process model based on energy and mass balances, including thermodynamic calculations for the most important metallurgical reactions, with particular focus on the modelling of the dephosphorisation reaction, as this is a critical parameter for production of high-quality steel grades along the EAF process route. A statistical scrap characterization tool is used to estimate the scrap properties, which are critical for reliable process performance and accurate online process control. The underlying process models and control functions were validated on the basis of historical production and measurement data of a large number of heats produced at the Sidenor plant. The online implementation of the model facilitates the accurate monitoring of the process behaviour and can be applied for exact process end-point control regarding melt temperature as well as oxygen, carbon and phosphorus content. Embedded within a model predictive control concept, the model can provide useful advice to the operator to adjust the relevant set-points for energy and resource-efficient process control