EAFAT Use Case: Introduction

The most typical use of EAFAT is as a tool for the Electric Arc Furnace (EAF) process
engineer to optimize and tune the electrical control system of the EAF. The following
document provides an example of how the EAFAT can be used by the process
engineer to segment the melting process into stages and develop operating points for
each stage based on high level requirements.
The examples in this document utilize EAFAT configured for one EAF in a facility with
two additional EAFs, three LMFs, a low short circuit level and a large static var
compensator (SVC).

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EAFAT Use Case: Model Adaptation

- EAFAT utilizes a
dynamic circuit model
to represent the nonlinear time-varying EAF
power system.
- EAFAT needs to be
configured for each
EAFs equipment
specifications, but also
must be adapted to the
particular EAFs
operational reactance.
- The model is adapted
using EAF electrical
measurements.

The electrical measurements also serve as a check on the configuration of the

EAFAT. If there is a problem with the configuration it will be obvious when
calculations are compared against measurements.
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EAFAT Use Case: Operational Goals

EAF power profiles are usually developed by segmenting the melting progress into
several stages. The actual number of stages depends on several factors. The use of
3 or 4 stages is common. Division of the melting progress into multiple stages
simplifies optimization of performance by converting the problem into multiple smaller
problems. Four stages are defined below with high level control goals for each.

Stage 1: Bore-In
- Keep arc length short
- Maintain good arc stability
- Utilize current regulation

Stage 2: Early Melt

- Use long arc
- Maximize arc RWI
- Maintain good arc stability
- Utilize impedance regulation

Stage 3: Main Melt

- Use long arc
- Increase arc power
- Maximize RWI if possible
- Utilize impedance regulation

Stage 4: Refine/Heating
- Decrease arc length
- Decrease arc power
- Observe phase balance
- Utilize impedance regulation

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EAFAT Use Case: Operational Goals

The table quantifies
operating point targets for
each melting stage. Can
not always perfectly
satisfy operating point
with AC EAF.
Fields denoted with a -
indicate that the value is
not a concern.
Melting stages are
normally indexed by some
combination of energy
(KWH), charge weight
(KWH/Ton) or stability
(THD). Indexes will be
neglected for this
example.

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Melt Stage

Arc MW

Arc RWI

Arc
Length

Bore-In

23 cm.

60 KA

Early Melt

~65 MW,
Below
peak

Maximize

35 cm.

< 60 KA

Main Melt

~70 MW,
Below
Peak

Maximize

40 cm.

< 60 KA

Refine/
Heating

55 MW

30 cm.

< 60 KA

I2

EAFAT Use Case: Bore-In

- Find a combination of reactor and EAF taps that provide a 23 cm arc length with good
stability.
- Using current regulation for bore-in. Chose 60KA set-point because it provides a good
current density for 600 mm electrodes.
- Using EAFAT configured for a facility with 3 EAFs and 3 LMFs. Will assume that other
EAFs and all LMFs are being operated throughout the examples.
- Arc power level is not so significant for bore-in. Will select a set-point of approximately 60
MW.
- Do not overload transformer(s)!

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EAFAT Use Case: Bore-In

1. Leave series reactance

out if possible
(Tap 9 = 0 ).

2. Reduce arc
stability control
to reflect bore-in
melting
conditions.

3. Set EAFs and

LMFs to on.

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4. Adjust Master
and EAF tap to find
desired EAF
operating point.

EAFAT Use Case: Bore-In

Arc length is 3
cm long, but
adequate as a
starting point.

Stability metrics indicate

this operating point will
have reasonable arc
stability.

Transformer loads are reasonable.

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Secondary current is
where we want it.
Arc power is a little low,
but adequate as a
starting point.

EAFAT Use Case: Bore-In

Did not need to utilize series reactance for this operating point. The arc is short enough
that it will be stable without it.
The operating point is a good starting point.

Heat Stage

Bore-In

EAF Tap

Reactor Tap

Control Mode

Current

Set-Point

60 KA

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EAFAT Use Case: Early Melt

- Find a combination of reactor and EAF taps that provide a 35 cm arc length with good
stability.
- Usually transition between stages in several intermediate steps (e.g. short to long arc,
low to high power, etc.). Will not do that here for the sake of brevity. Just be aware that it is
a good practice.
- Using impedance regulation for early melt.
- Want to keep secondary current below 60 KA to achieve good electrode consumption.
- Will continue to assume all EAFs and LMFs are in operation.
- Want to achieve approximately 65 MW with maximum arc RWI.
- Do not overload transformer(s)!

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EAFAT Use Case: Early Melt

1. Increase arc
stability control
to reflect early
melt conditions.

2. Leave EAFs
and LMFs set to
on.

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3. Adjust Master
and EAF tap to find
desired EAF
operating point.

4. Stability metrics
indicated slight
instability. Added a
small amount of
series reactance.

EAFAT Use Case: Early Melt

Arc RWI is at the
maximum.
Arc length is where
we want it to be.

With a small amount of series

reactance included, stability metrics
indicate this operating point will have
good arc stability.

Transformer loads are reasonable.

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EAFAT Use Case: Early Melt

Secondary
current is below
the 60 KA limit.

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Arc Power is
where we
want it and is
below peak.

Utilizing impedance
regulation. Will read
our set-point from
here.

EAFAT Use Case: Early Melt

Utilized a small amount of series reactance to improve arc stability. Could probably avoid
use of series reactance at this operating point with the correct scrap mixture.
Using impedance regulation. This is typically configured as the magnitude measured from
the EAF transformer primary to EAF dish ground.
All of the parameters are where we want them to be.

Heat Stage

Early Melt

EAF Tap

13

Reactor Tap

Control Mode

Impedance

Set-Point

4.5

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EAFAT Use Case: Late Melt

- Find a combination of reactor and EAF taps that provide a 40 cm arc length with good
stability.
- Usually transition between stages in several intermediate steps (e.g. short to long arc,
low to high power, etc.). Will not do that here for the sake of brevity. Just be aware that it is
a good practice.
- Using impedance regulation for late melt.
- Want to keep secondary current below 60 KA to achieve good electrode consumption.
- Will continue to assume all EAFs and LMFs are in operation.
- Want to achieve approximately 70 MW with maximum arc RWI.
- Do not overload transformer(s)!

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EAFAT Use Case: Late Melt

1. Increase arc
stability control
to reflect late
melt conditions.

2. Leave EAFs
and LMFs set to
on.

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3. Adjust Master
and EAF tap to find
desired EAF
operating point.

4. The additional
arc length required
that the series
reactance stay in
the system.

EAFAT Use Case: Late Melt

Could not maximize arc RWI
without overloading transformer.
Arc length is where we want it to
be.

The stability metrics indicate that this

operating point will have good arc
stability with a small amount of series
reactance added.

Transformer loads are good.

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EAFAT Use Case: Late Melt

Secondary
current is below
the 60 KA limit.

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Arc Power is
where we
want it and is
below peak.

Utilizing impedance
regulation. Will read
our set-point from
here.

EAFAT Use Case: Late Melt

Had to keep a small amount of series reactance in the system even though the arc
stability improved with melting progress. This is due to the use of higher secondary
voltage, and/or increased arc length.
Was not able to maximize RWI without overloading EAF transformer.
Using impedance regulation. This is typically configured as the magnitude measured from
the EAF transformer primary. Impedance set-point does not change from early melt stage.

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Heat Stage

Late Melt

EAF Tap

15

Reactor Tap

Control Mode

Impedance

Set-Point

4.5

EAFAT Use Case: Refine/Heating

- Find a combination of reactor and EAF taps that provide a 30 cm arc length.
- Stability will be good due to foamy slag. Should not require series reactance.
- Want to reduce arc power to 55 MW to slow down energy consumption. Heating rate is
less than linear with power input!
- Using impedance regulation for late melt. However, could use any control mode and get
reasonable results due to stable melting conditions.
- Want to keep secondary current below 60 KA to achieve good electrode consumption.
- Will continue to assume all EAFs and LMFs are in operation.
- All scrap is melted at this point and so RWI is not important. However, be cognizant of
phase balance. Refractory damage is most likely to occur during this stage if there are
large phase imbalances (>~ 15%) and poor slag conditions.
- The stability of this melting stage creates a situation where transformers (and other
components) can be easily overloaded in a continuous steady state. This stage is where
damage can really occur. Do not assume that transformer oil temperature is a good
indicator of loading.

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EAFAT Use Case: Refine/Heating

1. Increase arc
stability control
to reflect foamy
slag conditions.

2. Leave EAFs
and LMFs set to
on.

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3. Adjust Master
and EAF tap to find
desired EAF
operating point.

4. Take all series

reactance out. Will
not need it with
foamy slag.

EAFAT Use Case: Refine/Heating

Phase RWI imbalance is ~6%
which is not a concern.
Arc length is about where we
want it to be.

Dont usually need to worry about

stability at this stage, but the
indicators show that it will be good.

Transformer loads are good.

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EAFAT Use Case: Refine/Heating

Secondary
current is below
the 60 KA limit.

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Arc Power is
where we
want it.

Utilizing impedance
regulation. Will read
our set-point from
here.

EAFAT Use Case: Refine/Heating

A properly designed EAF electrical system should not need series reactance during foamy
slag melting conditions. Removed all series reactance.
Using impedance regulation. This is typically configured as the magnitude measured from
the EAF transformer primary to EAF dish ground.
Only use as much power as necessary. Will need to experiment to find out what the
minimum is. Will depend on amount of O2 used and melt-in Carbon levels. Using too much
power or arc length during this stage will result in poor energy efficiency.

Heat Stage

Refine/Heating

EAF Tap

Reactor Tap

Control Mode

Impedance

Set-Point

6.24

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EAFAT Use Case: Summary

Heat Stage

EAF Tap

Reactor
Tap

Bore-In

Current

60 KA

53 MW

60 KA

Early Melt

13

Impedance

4.5

65 MW

58 KA

Late Melt

15

Impedance

4.5

71 MW

55 KA

Heating

Impedance

6.24

55 MW

58 KA

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Control
Mode

Set-Point

Arc Power

Secondary
Current

EAFAT Use Case: Summary

Have shown how the EAFAT can be utilized to quickly develop and select operating
points for various stages of melting. With the baseline operating points established,
can develop transitions between stages and optimize set-points for each to achieve
the desired performance and efficiency.

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