Professional Documents
Culture Documents
Omar Quintanilla
Regulation Engineer
Nucor-Yamato Steel Company
5929 Highway 18 East
Armorel Arkansas 72310
870-762 5500 ext 146
oquintanilla@nucor-yamato.com
Guillermo Fernandez
Technology Manager
AMIGE International
Blvd Gustavo Diaz Ordaz 402 Piso 2
Monterrey NL, México 64650
(52) (81) 1001-4076
gfernandez@amige.com
Introduction
Nucor Yamato Steel is continuously working to improve the operations all time. The energy input optimization has always been
at a good performance level, but there is always been turnarounds on the way to achieve better results. The most difficult part
of the adjustment process is that the control system is divided into several control sub-systems which interact between each
other. These sub-systems do not take into account the effects of changes made to another sub-systems, and are developed by
different vendors in their own knowledge area. As an example, reducing the exhaust gas negative pressure may produce less
energy losses, but it may cause the furnace to be more prone to cross-arcing and so to damages and loss of time. In order to
optimize the EAF process as a whole, new SmartFurnace modules were added to the SmartArc system. The SmartArc control
system has been in place since 1997 for controlling the electrical energy input at NYS. The new SmartFurnace modules were
added in order to take on-line control of the Burner System and the Exhaust Gas system. In this paper we will first present a
description of the EAF system, then we’ll talk about the main issues in the pursue of high performance, then we will present a
brief description of the new control modules and their added flexibility in order to cope with the main variations in the other sub-
systems. Finally we’ll show some of the new features tested and the evolution of some of the adjustments and the results.
System description
Electrical System
NYS has an AC EAF with a 90MVA transformer with a two position online reactor. Using a 0.609 meter electrode diameter in a in
a 1.12 meter pitch circle diameter.
Figure 3. The Table has the transformer low voltage amps and volts in all the tap positions.
Xfrmr tap 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
Sec volts 929 940 947 958 966 978 986 994 1,002 1,015 1,023 1,036 1,045 1,055 1,064 1,078 1,088 1,098
HV current 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506
A
LV cuerrent 55.94 55.30 54.87 54.22 53.79 53.14 52.71 52.28 51.85 51.21 50.78 50.13 49.70 49.27 48.84 48.20 47.77 47.34
kA
MVA 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0
Burner System
Four burners are located around the shell generating 6.9 MW
each.
The three port burners are used in Burner Mode creating
combustion between low flow oxygen and natural gas, the Lance
Mode uses supersonic oxygen flow and injected carbon.
Shell
The shell was designed to tap 122 metric tons and handle 10% of
hot heal.
System Control
The old AMIGE regulator ARCMeter was replaced by the DigitARC Plus in March 2007, also the new SmartArc version was
installed. The electrical system was improved with this change, regulation (electrode movement), and electrical profiles were
adjusted to have a better performance.
Figure 5. Power-on time since 2000 in both furnaces. The furnaces have the same characteristics.
Still some improvement was needed in the chemical side, NYS decided to implement a project to optimize the EAF Operation. As
part of this project new SmartFurnace modules where added to the SmartARC. These modules control the burners, Carbon
Injection, the Furnace pressure ad a new furnace balance.
The mentioned obstacles are the most remarkable, because they create higher power off time and are the ones that are at NYS
aim.
MWH is the simple way to control the steps, without considering that the scrap varies all the time, weight, density, type. As we
mentioned earlier variables like OperationalKWH/Ton and Stability Factor will make a more accurate profile.
OperationalKWH/Ton is useful to apply the same chemical energy to one ton of steel, helping the furnace operators to become
constant in the steel chemical composition and slag properties at the end of the heat.
Stability, in the other hand, could make your profile to be opposed to some of the OperationalKWH/Ton benefits, just if your
electrical profile is not also reacting to electrical stability, if the scarp density is too high or it didn’t fall evenly during the melting
down process, waiting on stability will remove some chemical energy from the furnace but help the user to avoid blow-backs. A
blow-back is produced any time the supersonic oxygen lances in the burners are run in lance mode with a thick or big piece of
scrap in the front of the lances. Normally this happens too early in the heat, this cause the oxygen to be redirected to the
furnace walls, creating a damage during long periods of time.
The Carbon Jet Cycle (CJ_Cycle) and the Oxygen Jet Cycle (OJ_Cycle) were created by AMIGE to be used during the burner
mode, this are time based repetitive cycles. The cycles modify the burner set-points to create different patters in the melted
scrap in front of the burner to prepare the area for the supersonic oxygen lance to avoid blow-backs and have a more efficient
lance going to the bath. This allows the users to introduce more chemical energy and earlier in the heat.
The injected oxygen reacts with some scarp components like Carbon (C), Silicon (Si) and Manganese (Mn), as well as the injected
Carbon (C), and Natural Gas (Methane CH4, as primary component).
Figure 7. The chart show the energy generated by some combustibles involved in the EAF process.
The manufacturers of the burners intended the supersonic oxygen ports to work at a nominal flow, if the working flow is
increased above the nominal, the lance become less efficient, but still add extra oxygen to bath. This extra oxygen needs more
components to react with, carbon as an example, the extra oxygen will take more carbon from the scrap and the injected
carbon, generating more energy and raising the temperature in the bath faster. That could sound like using less KWH/Ton in the
heat, but also changes the carbon content in the melted steel, the carbon amount to react with FeO in the slag, the amount on
needed minerals at the end of the heat.
The use of the OperationalKWH/Ton help the users to add this extra oxygen in an ‘efficient’ way. The increase of the oxygen flow
generates an increase in the lances oxidation rate, reacting faster with the present components, since the C, Si and Mn are a
limited source the higher oxidation rate will have more impact in low weight heats and scrap with low components value. The
use of this variable equalizes the impact to different weight heats and helps the users to have a benefit of that extra oxygen
used in the heat.
Figure 8. The figure shows the step variables and cycles used for one burner at the second charge.
Variables like MW, KWH/Ton, Sf (Stability Factor), O2PPM are used in the same step.
The logic also has a panel temperature protection, which turns of the lances during long periods of blow-backs. This function
extend the panel life. The logic is also included in the SmartArc.
Different variables can be use to jump from one step to the other. N YS is using two more variables to manage the programs,
Free02 and O2PPM (Oxygen Parts Per Million) . These variables can be used for the same purpose the difference is the units, both
are estimating the amount of oxygen present in the molten steel. The FreeO2 variable generated by the SmartArc is estimating
the oxidation level in the bath, the O2PPM variable is generated from the Free02 for easy use.
The O2PPM variable estimates the oxygen part per million present in the molten steel. This variable is not only useful to use the
adequate amount of oxygen during the heat, also allows the users to end the heat in a certain range of O2Ppm. This kills power
of time at the end of the heat (Decarburization Time).
Figure 10. The horizontal line is based on time, with forty heat data. The dark dots have the
Oxygen Ppm value from the furnace sampler, the shady dots represent the estimated Ppm value from
SmartArc when the sample was taken.
Summary
In the following charts the results of all the improvements are shown.
31.0
30.0
29.0
P ower On T ime
28.0
27.0
26.0
25.0
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 14
Wk 16
Wk 18
Wk 20
Wk 22
Wk 24
Wk 26
Wk 28
Wk 30
Wk 32
Wk 34
Wk 36
Wk 39
Wk 41
Wk 43
Wk 45
Wk 47
Wk 49
Wk 51
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 13
Wk 15
Week #
Figure 11. Average Power On Time by week. Wk1 in the horizontal axis at the left, means the week number one in 2007 (Sunday 31st, on
December 2006 to Saturday 6th, on January 2007).
E AF Averag e Meg Watts Ave E lectrical P ower Input (MW )
92.0
90.0
88.0
A verag e Meg aWatts
86.0
84.0
82.0
80.0
78.0
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 14
Wk 16
Wk 18
Wk 20
Wk 22
Wk 24
Wk 26
Wk 28
Wk 30
Wk 32
Wk 34
Wk 36
Wk 39
Wk 41
Wk 43
Wk 45
Wk 47
Wk 49
Wk 51
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 13
Wk 15
Week #
Figure 12. Average Megawatts by week. Wk1 in the horizontal axis at the left, means the week number one in 2007 (Sunday 31st, on December
2006 to Saturday 6th, on January 2007).
31.0 1440.0
1420.0
30.0
1400.0
1380.0
29.0
O xyg en S C F / T on
P ower O n T ime
1360.0
28.0 1340.0
1320.0
27.0
1300.0
1280.0
26.0
1260.0
25.0 1240.0
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 14
Wk 16
Wk 18
Wk 20
Wk 22
Wk 24
Wk 26
Wk 28
Wk 30
Wk 32
Wk 34
Wk 36
Wk 39
Wk 41
Wk 43
Wk 45
Wk 47
Wk 49
Wk 51
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 13
Wk 15
Week #
Figure 13.Oxygen usage per ton and Power on time. Wk1 in the horizontal axis at the left, means the week number one in 2007 (Sunday 31st,
on December 2006 to Saturday 6th, on January 2007).
Natural G as Us ag e / T on vs . P ower O n T ime
Ave P ower on time (min) Ave Natural G as C ons umption (S C F /ton)
31.0 280.0
270.0
30.0
260.0
29.0
C H4 / S C F / T on
P ower O n T ime
250.0
28.0
240.0
27.0
230.0
26.0
220.0
25.0 210.0
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 14
Wk 16
Wk 18
Wk 20
Wk 22
Wk 24
Wk 26
Wk 28
Wk 30
Wk 32
Wk 34
Wk 36
Wk 39
Wk 41
Wk 43
Wk 45
Wk 47
Wk 49
Wk 51
Wk 1
Wk 3
Wk 5
Wk 7
Wk 9
Wk 11
Wk 13
Wk 15
Week #
Figure 13.Natural Gas usage per ton and Power on time. Wk1 in the horizontal axis at the left, means the week number one in 2007 (Sunday
31st, on December 2006 to Saturday 6th, on January 2007).
4. References.
Richard J. Fruehan, “The Making, Shaping and Treating of Steel,” 11th. Edition.
The AISE Steel Foundation., Pittsburg, PA, 1998, pp. 311-395