Improvement of the Foaming Agent Feeding Process to an Electric Arc Furnace by Analyzing the Sound Generated by an Electric Arc and the Coefficient of Variation of Active Power Consumption

Electric arc furnaces are commonly used in foamed slag technology for the production of steel from steel scrap through an electric process. The effects of using this technology include increased efficiency, reduced consumption of refractory materials, reduced energy consumption, reduced electrode wear, and improved arc stability. The world is constantly looking for solutions to optimize the feeding of the foaming agent to the electric furnace, including determining the moment of starting its feeding. The authors propose using two parameters to determine the optimal moment of introducing the foaming agent: the change in the sound level emitted by the arc furnace and the fluctuations in active power consumption. In order to determine the above parameters, tests were carried out on an industrial alternating UHP arc furnace with a capacity of 70 tons. The sound intensity level was determined at which the feeding of the foaming agent to the furnace’s working space should begin. A moving coefficient of power consumption variation was developed and decision variables of the software for online foaming agent feeding were determined. As a result of implementing the developed solutions to the electric furnace control system and conducting comparative tests, savings were obtained in the form of reduced foaming agent consumption.