Magnetic field-based arc stability sensor for electric arc furnaces

During the last decades the strategy to define the optimal Electric Arc Furnaces (EAF) electrical operational parameters has been constantly evolving. Foaming slag practice is currently used to allow high power factors that ensures higher energy efficiency. However, this performance depends on strict electric arc stability control. Control strategies for these are normally defined for alternating current furnaces (AC EAF) and are based on intrusive and highly expensive systems. In this work we analyze the variation of the magnetic field vector around the direct current EAF (DC EAF) and its relationship with arc stability. We propose a cheap stability control system with no installation or integration requirements and thus, easily implementable to both AC and DC EAFs. To this end we have built a non-intrusive and low-cost 3-axis Hall-effect sensor that can be mounted neighboring the furnace's electrical bars. The sensor allows acquiring the magnetic field magnitude and orientation that provides a newly defined arc stability factor metric. This proposed Arc Stability Index has been compared with three different alternative well established and more expensive measurement methodologies obtaining with similar results. The proposed index serves as a closed loop signal to the electrical regulation for controlling the arc voltage, ensuring the most convenient arc length that guaranties non-instabilities. The new system was developed and industrially validated at two different DC EAF's in ArcelorMittal demonstrating an improvement of 6.7 kWh per Liquid steel ton during the evaluated period and a time reduction of 1.1 min per heat over the current standard procedure. Additional validation tests were also carried out also in ArcelorMittal AC EAF proving the capability of this technology for both AC and DC of furnaces. (C) 2019 Elsevier Ltd. All rights reserved.