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MODELLING AND CONTROL OF A THREE-PHASE ELECTRIC ARC FURNACE

M. Peens, I.K. Craig and P.C. Pistorius*

Department of Electrical, Electronic and Computer Engineering, University of


Pretoria, Pretoria, 0002, South Africa, e-mail: icraig@postino.up.ac.za
Department of Materials Science and Metallurgical Engineering, University of
Pretoria, Pretoria, 0002, South Africa

Abstract: This paper investigates the modelling and control of the electric energy input of
a three-phase electric arc furnace (EAF) using electrode position control as the main
control strategy. Two methods to keep the electrical energy input constant at a known set
point value are to control the arc-current or the arc-impedance. These variables are
controlled by moving the electrodes up or down using an electrode position controller.
Plant data are used to do system identification on an industrial EAF to model the close
loop electrode system. Copyright © 2003 IFAC
Keywords: Electrodes; Arc resistance; Modelling; Ward Leonard drive; Control; Step
inputs

1. INTRODUCTION controlled via an electrode position controller which


moves the electrodes in a vertical position to adjust
EAFs produce steel by melting scrap using a three- the arc current or arc impedance according to
phase electrical supply as the electrical energy input. specified reference values (Billings et. al., 1979).
The fundamental problem in the EAF industry is the
production of steel at a specified quality at the lowest Some electrode position controllers used in the
cost possible. This three-phase electrical input serves 1970’s made use of a well known Ward Leonard
as the main energy input in the electric arc furnace. drive to position the electrodes (Billings and
The electrical energy input needs to be controlled Nicholson, 1977). In this paper a mathematical
with the aim of achieving the lowest possible model of an electric arc furnace with a Ward-
production cost. Leonard drive in the controller is used to investigate
the control of a three-phase electric arc furnace.
Each phase of the three-phase electrical input
supplies power to one of the three electrodes that is Most modern EAFs use newly designed hydraulic
mounted above the furnace bath through the roof. systems to move the electrodes and although Ward
The furnace roof is closed when power is supplied to Leonard drives are not commonly used anymore it
the system. The furnace operation is based on heat can still be used to compare different control
transfer into the bath from arcs drawn between the strategies.
tips of the electrodes to the metallic charge. Thus,
electrical energy is converted into heat which is Section 2 of this paper introduces the model for the
transmitted to the charge through the electrodes electrical energy input of an electric arc furnace. The
(Billings and Nicholson, 1975). Constant melting model used for arc impedance control is different
causes the arc length to change and results in a from the model that is used for arc current control.
change in the electric energy input if control is not Both these models are described in section 2. Section
supplied to the system. Two variables are mainly 3 describes the modelling and simulation of an
used to control the electrical energy input, i.e. arc electrode position controller that makes use of a
impedance and arc current. Both these variables are
Ward-Leonard drive to change the position of the
electrodes. In section 4 industrial data are used to do
system identification of the EAF. The data that were
used for the system identification comes from a plant
that uses more modern techniques than that of the
current model discussed.

2. MODEL DESCRIPTION

The EAF electrical input is supplied from a furnace


transformer which in our case is three-phase. Each of
the three phases serves as a power input to one of the
three electrodes.

Depending on the control strategy, an electrode


position controller might be necessary for each of the
electrodes. Single phase modelling is thus needed for
realistic simulation. A single phase representation for
the electrical energy input to the EAF is shown in
figure 1 (Billings and Nicholson, 1975).

The furnace transmission system from the power Fig. 1. Electrical power supply system (single phase)
generation system to the arcs is described by the (Billings and Nicholson, 1977)
following equations (Billings and Nicholson, 1975):

gives the arc current, arc resistance relationships as


E ( h' Z t 2 − Z t 3 )
I1 = (1) follow with k ≠ l (Billings and Nicholson, 1975):
3
( ∑ Z tk Z tl )
k ,l =1
3 3
(− I 1o ) 3 [( Rt 2 + Rt 3 )[ ∑ ( Rtk Rtl − X k X l )] + ( X 3 + X 2 )( ∑ Rtk X l )]
i1 k ,l =1 k ,l =1
=
ra1 E 2 [( − Rt 3 − Rt 2 / 2 − 3 X 2 / 2) 2 + ( 3Rt 2 / 2 − X 2 / 2 − X 3 ) 2 ]
'2
E ( Z t 3 − h Z t1 ) (7)
I2 = (2)
3
( ∑ Z tk Z tl ) 3 3
(− I 2o ) 3 [( Rt 2 + Rt 3 )[ ∑ ( Rtk Rtl − X k X l )] + ( X 1 + X 3 )( ∑ Rtk X l )]
k ,l =1 i2 k ,l =1 k ,l =1
=
ra 2 E 2 [( Rt 3 − Rt1 / 2 − 3 X 1 / 2) 2 + ( X 3 − X 1 / 2 + 3Rt1 / 2) 2 ]

E ( h ' 2 Z t 1 − h' Z t 2 ) , k ≠ 1 (8)


I3 = 3
(3)
( ∑ Z tk Z tl )
3 3
(− I 3o ) 3 [( Rt 2 + Rt 3 )[ ∑ ( Rtk Rtl − X k X l )] + ( X 1 + X 2 )( ∑ Rtk X l )]
i3 k ,l =1 k ,l =1
k ,l =1 = 2
ra 3 E / 4[(− Rt1 + 3 X 1 + Rt 2 + 3 X 2 ) 2 + (− X 1 − 3Rt1 + X 2 − 3Rt 2 ) 2 ]
(9)
z tk = ( Rak + Rck ) + jX k = Rtk + jX k
( k = 1,2,3) (4) or

where Ztk is the total phase impedance referred to the ik = − Fk rak (10)
transformer secondary windings, Rak represent arc
resistance, Rak is the system line resistance, Xk is the The arc discharge model for the system can be found
line reactance, E is the line voltage and h’ is a by using Nottingham’s equation that relates arc
complex three-phase operator. voltage and arc length.

The current magnitudes can then be linearised with a C k + Bk H k


first order Taylor series expansion with Vak = Ak + Dk H k + (11)
I kn
o (5)
I k = I k + ik
Hk is the effective arc length and Dk is the arc-
discharge coefficient. The arc-discharge coefficient is
and a function of the ambient arc temperature.
o (6)
R ai = R ai + rai A linearised version of the voltage measured at the
transformer secondary terminal provides one of the
Assuming zero interaction between the three arc components for the error current used as controller
resistances and an infinitely stiff supply voltage input and can be expressed as follows:

−1
v mk = i k Z tk + rak I ko ( Rak + Rck ) Z tk (12)
In the arc-impedance-controlled model the error
where signal feedback can be represented by:

Z tk = [( Rak + Rck ) 2 + X k2 ]1 / 2 (13) ε k = G5 ik − G4 vmk , k = 1,2,3 (22)


I k = I + ik
o
k
(14)
where G4 and G5 are constants associated with the
Rak = Rako + rak (15) arc-impedance measuring circuit. Eliminating vmk and
ik using equations (17) and (18) gives the three-phase
transmission system model when using arc-
Using equation (10) gives impedance control and can be presented as follow:

Fk Dk hk ε k = −[G 4 D' k +G5 (WD) k ]hk , k = 1,2,3


ik = (16)
Fk Rako − I ko (23)

or
2.2 Model description for arc current control
i k = −(WD ) k hk (17) Current control, where the magnitude of the phase
currents are controlled, produces inherent interaction
where WD is constant and are usually called the arc between the three different currents and also between
gain. After substituting equation (17) into equation the electrode position controllers. When a
(12), the relationship between the change in the disturbance occurs on one of the electrode positions
measured voltage vmk and the arc length hk is defined all the arc currents will change and control must be
by: applied to all three phases. In the process all the arc-
resistances and the arc-lengths will change.
−1
vmk = Dk hk [(1 − Wk Rck )( Rako + Rck ) − Wk X k2 ]Z tk  Consequently, linearising equations (7), (8) and (9)
using a first-order Taylor series expansion with
(18)

or I k = I ko + ik (24)

v mk = D' k hk k = 1,2,3 (19) and

From here models have to be derive separately Rak = Rako + rak , k = 1,2,3 (25)
depending on the type of control method used.
give, (for k ≠ l ):

2.1 Model description for arc impedance control E 2 [α 1 ra1 + β 1 ra 2 + γ 1 ra 3 ]


i1 = 3 3
Arc-impedance control is based on maintaining the I 1o [( ∑ Rtk Rtl − X k X l ) 2 + ( ∑ Rtk X l ) 2 ] 2
arc-impedance at a constant preset value determined k ,l =1 k ,l =1
by the tap setting on the transformers secondary
(26)
terminal. The advantage of this method is that there
is none or little interaction between the arc-
impedances of the three different phases. E 2 [α 2 ra1 + β 2 ra 2 + γ 3 ra 3 ]
i2 = 3 3

Eliminating vmk and ik from equation (19) and I 2o [( ∑ Rtk Rtl − X k X l ) 2 + ( ∑ Rtk X l ) 2 ]2
rearranging gives the arc resistance/arc length k ,l =1 k ,l =1

relationship as follow: (27)

hk ( D ' k +(WD) k Z tk ) E 2 [α 3 ra1 + β 3 ra 2 + γ 3 ra 3 ]


rak = (20) i3 = 3 3
−1
I ko Rtk Z tk I 3o [( ∑ Rtk Rtl − X k X l ) 2 + ( ∑ Rtk X l ) 2 ] 2
k ,l =1 k ,l =1

or (28)

rak = Bk hk k = 1,2,3 (21) These equations relate the change in arc current to
the changes in arc resistances as the latter are
adjusted by the electrode position controllers.
Each of the arc resistances is represented as a Eliminating ra1, ra2 and ra3 using equation (21) gives
function only of its associated arc length and the arc the current controlled model as follow:
characteristics D and D’.
 B1α 1 B2 β 1 B 3γ 1 
 o 
 i1   I1 I 1o I 1o 
i  = E 2
 B1α 2 B2 β 2 B3γ 2 
 2 3 3  Io I 2o I 2o 
i3  [( ∑ Rtk Rtl − X k X l ) + ( ∑ Rtk X l ) ]  2 
2 2 2

k ,l =1 k ,l =1  B1α 3 B2 β 3 B 3γ 3 
 Io I 3o I 3o 
 3
(29)

with k ≠ l where α k , β k and γ k are constants.

In the current-controlled model the error feedback is


defined as follow:

ε k = − Ak i k , k = 1,2,3 (30)

where the scalar Ak is chosen such that the error


current is initially equal for both current- and Fig. 2. A single phase electrode position controller
(Billings and Nicholson, 1975)
impedance controlled regulators.

3. THE ELECTRODE POSITION CONTROLLER

Throughout the period of a melt the arc length varies


erratically due to scrap movement within the furnace
and some form of control is required to maintain the
desired power input level. The function of an arc
furnace electrode position controller is to maintain a
preset arc current or arc impedance by lowering or
raising an electrode. Electrode position controllers
use the current-voltage reference feedback from the
furnace power system to position the electrodes.

The regulator discussed in this paper employ a Ward


Leonard drive to position the electrodes. However,
regulating systems have successfully been
introduced. These systems use modern technology
and solid state electronic components but will not be Fig. 3. Block diagram of the electrode position
discussed in this paper due to the lack of open controller (Nicholson and Roebuck, 1972)
literature. Most references on this topic date back to
the 1970’s. and produces an error when they are unequal. The
following transfer function, that relates the error
current in the amplidyne control winding to the
3.1 Modelling the electrode position controller output mast position, is determined from fig.3:

An electric arc furnace process consists of three z −2T (0.2498 z −1 + 0.3079 z −2 + 0.095 z −3 )
different electrode position controllers, one for each g kk ( z −1 ) =
1 − 3.547 z −1 + 4.826 z − 2 − 2.9967 z −3 + 0.7177 z − 4
of the three electrodes. All three regulators work on (31)
the same basis.
The step time for this digital transfer function is
A circuit diagram of an electrode position controller usually taken as 1/24 seconds to assure an accurate
using a Ward-Leonard-drive together with an model for the arc furnace controller.
amplidyne amplifier is shown in fig. 2. Modelling of
the electrode position controller is based on Two separate arrangements are needed for arc
modelling each component in the system impedance control and arc current control. Figure 1
individually. Fig. 3 shows the block diagram and figure 2 can simply be combined when the
representing the different transfer functions for each control strategy is based on maintaining the arc
component. impedance at a constant value. Note that this will
represent a single phase arrangement as the three
In the controller under discussion the error signal different arc impedances do not show any interaction.
acts as the input to an amplidyne rotating amplifier Figure 4 shows another arrangement where current
and the output of the amplidyne provides the input to control is used to maintain the input power at a
the Ward Leonard drive and the winch system moves constant preset value. The three phases, when
the electrode up or down. The arc-impedance looking at arc currents, have a fair amount of
measuring circuit compares currents proportional to interaction between them which calls for a combined
arc voltage and arc current with a reference value control strategy.
Fig. 4. Block diagram of the current controlled arc
furnace (Billings, et al., 1979)

To implement current control for the arc furnace one


can combine the model obtained in equation (29) Fig. 5. Simulation results. The solid lines are current
with the electrode position controller model in control and the dashed lines are impedance control
equation (31). The current- and impedance- (Nicholson and Roebuck, 1972)
controlled models have been formulated assuming
equal arc characteristics and electrode-position impedance control may be advantageous under short
controller dynamics. circuit conditions. This results in the possibility to
use these two control strategies in a dual method
When a disturbance occurs in the arc furnace the where impedance control is used when the system is
electrode position controllers operate in response to operating under normal melting conditions and
an error between the controlled variable and its current control when a short circuit on one of the
referenced value to adjust the electrode position and phases occur.
re-establish the desired power input. A performance
measure of the electrode-position controller can 4. SYSTEM IDENTIFICATION ON THE EAF
therefore be based on its ability to re-establish the
desired input power while maintaining necessary Measured data from an industrial EAF can be used to
control constraints. verify electrode position control. However, the plant
where the data were obtained from does not use a
Ward-Leonard drive as part of the electrode position
3.2 Simulation results controller.

The models were simulated assuming equal arc The industrial data obtained included two hours of
characteristics (D’=3940V/m) and electrode-position recorded data for the arc currents. Live
controller dynamics for each phase. Time steps of measurements together with reference values were
1/24sec were used throughout the simulations. obtained. The date can be used as input and output
data for a close loop system identification on the
The responses of the current- and impedance EAF. Data were also obtained for the input power
controlled models with a disturbance of 1.25 cm on and the voltage measured at the secondary terminals
one of the arc lengths are shown in Fig. 5. of the furnace transformer. The three parameters
mentioned above are directly proportional to each
From fig. 5 (Nicholson and Roebuck, 1972) we can other. Figure 6 shows the set point data (input) and
clearly see that the current control strategy results in the actual measured data (output) for the first phase
a larger accumulated power discrepancy compared of an industrial electric arc furnace during an entire
with impedance control. The reason for this is production phase. The data were sampled at 1 second
because of the direct interaction between the phase intervals. This gives a total time of 50 minutes of
currents. This means that although only one phase is data.
triggered with a disturbance all three electrode
controllers act to establish the preset input power. With three different phases to control and assuming
inherent interaction between them gives a total of
The ability of the current control strategy to reduce nine transfer functions needed. The system can be
the arc-current deviations in a shorter time than arc represented by the following equation:
OUTPUT #1 Step Response
80 From: U(1)
0.9

60
0.8

40
0.7

20
0.6

Amplitude (kA)
0
0 1000 2000 3000 4000 5000 6000 7000 0.5

To: Y(1)
INPUT #1
0.4

55
0.3
arc-current (kA)

50
0.2

45 0.1

40 0
0 14 28 42 56 70
0 1000 2000 3000 4000 5000 6000 7000
samples time (sec)

Fig. 6. Set point current and measured current Fig. 7. Step response for T11(s)

 i1  T11 ( s ) T12 ( s ) T13 ( s)   is1  current control furnace. These models can be
i  = T ( s ) T ( s) T ( s ) i  simulated to show the response of the electrode
(32)
 2   21 22 23  s2  movements when disturbances are applied to the
i3  T31 ( s ) T32 ( s) T33 ( s)  is 3  system.

Simulation results show that arc-impedance and arc-


In this paper however only T11(s) will be given
current control can achieve effective control for the
because the other diagonal transfer functions are
electrode tip displacement during the production of
similar. The system identification was done by using
steel. The differences between these two methods
an ARX (Auto Regression with external input)
show that arc-impedance control is more efficient
model. The model for T11(s) was determined in the
during normal control while interacting current
following format:
control can be more efficient when removing short
circuits.
ke − is
T11 ( s) = (34)
τs + 1 With accurate modelling of the system more efficient
control, and hence lower production costs, can be
where k is the dc gain and should be one for perfect achieved in electric arc furnace steelmaking.
control, i is the time delay and τ is the time constant.
ACKWOLEDGEMENT
The following result was obtained: This material is based on work supported by the
National Research Foundation under Grant number
2053268. Any opinion, findings and conclusions or
0.883e −5 s recommendations expressed in this material are those
T11 ( s ) = (35)
11.127 s + 1 of the author(s) and do not reflect the views of the
National Research Foundation.
A step response of this model in figure 7 show that
the arc current, with electrode control in place, are REFERENCES
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Billings S.A. and H. Nicholson (1977). Modelling a
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