Modeling and Simulation of the Off-gas in an Electric Arc Furnace
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The following paper describes an approach to process modeling and simulation of the gas phase in an electric arc furnace (EAF). The work presented represents the continuation of research by Logar, Dovzˇan, and Sˇkrjanc on modeling the heat and mass transfer and the thermochemistry in an EAF. Due to the lack of off-gas measurements, Logar et al. modeled a simplified gas phase under consideration of five gas components and simplified chemical reactions. The off-gas is one of the main continuously measurable EAF process values and the off-gas flow represents a heat loss up to 30 pct of the entire EAF energy input. Therefore, gas phase modeling offers further development opportunities for future EAF optimization. This paper presents the enhancement of the previous EAF gas phase modeling by the consideration of additional gas components and a more detailed heat and mass transfer modeling. In order to avoid the increase of simulation time due to more complex modeling, the EAF model has been newly implemented to use an efficient numerical solver for ordinary differential equations. Compared to the original model, the chemical components H2, H2O, and CH4 are included in the gas phase and equilibrium reactions are implemented. The results show high levels of similarity between the measured operational data from an industrial scale EAF and the theoretical data from the simulation within a reasonable simulation time. In the future, the dynamic EAF model will be applicable for on- and offline optimizations, e.g., to analyze alternative input materials and mode of operations. DOI: 10.1007/s11663-017-1093-7 The Minerals, Metals & Materials Society and ASM International 2017
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INTRODUCTION
ELECTRIC steelmaking in an electric arc furnace (EAF) is the main process route for steel scrap recycling and the second most important steel production route in the world. As an energy-intensive process, the EAF is responsible for approximately 3 pct of the total industrial electricity consumption and a significant lever for energy efficiency optimization.[1] As the off-gas flow represents an energy output of 20 to 30 pct of the total EAF energy input, the off-gas is in the focus of current developments to increase the energy and resource efficiency of the EAF. As one of the main continuously measurable process values, the off-gas composition can be utilized to improve the process control and allows conclusions to be made concerning the process behavior. Here, process models have proven their applicability for process control and their capability to contribute toward a more detailed THOMAS MEIER, KARIMA GANDT, THOMAS ECHTERHOF, and HERBERT PFEIFER are with the Department for Industrial Furnaces and Heat Engineering, RWTH Aachen University, Kopernikusstrasse 10, 52074 Aachen, Germany. Contact e-mail: [email protected] Manuscript submitted March 24, 2017.
METALLURGICAL AND MATERIALS TRANSACTIONS B
understanding of heat and mass transfer during the melting process. In times of continuously growing computational capacity, the complexity of the dyn
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