Adaptive EAF online control based on innovative sensors and comprehensive models for improved yield and energy efficiency (AdaptEAF) : final report

The objective of the pilot and demonstration project AdaptEAF was to complement modern EAF process control by integrating novel sensor data and advanced process modelling tools, and to test and evaluate this adaptive EAF process control under industrial conditions at the 140 t DC Electric Arc Furnace of Georgsmarienhütte (GMH). Novel sensors were installed at the EAF of GMH, aiming to provide additional process information for online control. For determination of steel, hot heel and slag amounts a dip sensor to measure steel and slag levels was implemented, and an imaging system to monitor the bath level in the furnace was installed. An imaging system was also used to estimate the filling level of the scrap baskets. Vibration sensors at the furnace vessel were applied to monitor the scrap melting progress. The additional process information was integrated in the EAF process data base and operator display and used as inputs for extension of process models and development of control tools. Adapted operating diagrams for control of the chemical energy input depending on the actually charged scrap mix were defined, and quality dependent strategies for end-point control were developed. A procedure to determine the optimal point of time for charging the second scrap basket was set up and validated. The steel bath level is controlled on the basis of the dip sensor measurement. Finally plant trials for online test and validation of the enhanced process control tools have been performed and evaluated in terms of achieved savings in energy input and treatment time.