Tenova’s iEAF® is a progressive, modular technology package designed to provide EAF steelmakers with sustainable long-term savings from dynamic control and holistic optimization of the EAF process.
Tenova's innovative iEAF® , "intelligent Electric Arc Furnace", is breakthrough technology that combines proven off-gas analysis, novel sensors and process models to provide an unparalleled level of EAF process control, safety and energy efficiency.
Based on real-time measuring of EAF off-gas composition and temperature, mass & energy balances and in conjunction with real-time process inputs, dynamic information is revealed to determine; mass-rate of off-gas leaving the EAF; rate of air-inleakage; rate of decarburization; rate of oxidation; rate of water entering the freeboard of the EAF and the contribution of chemical energy to the heating and melting of steel.
iEAF® controlled furnaces are paced according to the total energy (electrical plus chemical) supplied to the scrap. Combustion optimization is achieved by closed-loop control of burner oxygen and methane based on calculated (not estimated) heat transfer efficiencies and economics. Control of carbon and oxygen injection, via dynamic state-space modeling of the slag and bath composition, make it possible to maintain optimal slag properties for effective slag foaming over the whole of the refining period.
iEAF® enabling technology can be applied to all variations of the EAF process including: top charge melting furnaces using scrap, DRI and/or pig iron; the Consteel process with or without hot metal; continuous DRI fed furnaces.
The iEAF® technology package with well-defined Modules allows EAF melt shops to improve process control, reduce energy consumption & operating costs, increase productivity and lower emissions in a progressive stepwise fashion.
Each sequential step in the iEAF® program utilizes a combination of real-time measurements, dynamic process inputs and on-line process models.
While the iEAF® can be easily integrated with any existing automation and process control system, the cornerstone and necessary first step in the iEAF® technology program is the NextGen® technology; other off-gas analysis methods which cannot provide complete analysis of CO, CO2, H2 and O2 lack a necessary prerequisite for determining an online Mass & Energy Balance which is critical for efficient energy utilization and effective dynamic control of the melting and refining processes.
The technology consists of:
Module 1 - Dynamic Chemical Energy Control & Optimization
"In-EAF" is based on the proven NextGen® technology with guaranteed optimal "In-EAF" chemical energy utilization. Optimization of the burner, lance and injector using a proven closed loop control methodology that is fully integrated with the plant automation system, locks in the optimized practice. Dynamic control of the furnace atmosphere can be used to avoid over- or under-drafting conditions, maximizing overall energy efficiency but also minimizing yield loss, electrode consumption and refractory wear that can be exacerbated when the freeboard is over oxidizing.
Benefits include reduced operating costs; carbon, oxygen, methane, and electrical energy consumption; electrode and refractory consumption and reduced emissions; while increasing productivity and yield.
Module 2 - Dynamic Melting Control
Utilizes novel sensors combined with on-line process models to pace the EAF operation for mass energy balance. Novel sensors such as off-gas temperature/pressure/flow-rate are used along with slag and liquid weight measurement or calculation.
With the iEAF® approach, heat control is based on real-time calculation of the melting percentage, rather than on the traditional kWh per ton method which is ground-breaking innovation in the pacing of EAF operations. Benefits include further reductions in total energy consumption; Power on Time; while correcting timing for bucket charging and providing precise onset knowledge of flat bath condition.
Module 3 - Dynamic End-Point Control
Facilitates dynamic control of the refining process so that end-point temperature and carbon conditions can be reached. Through determining the optimal strategy to reach the end-point conditions in terms of liquid steel temperature and carbon content. The module uses data from the novel sensors combined with Bath & Slag process control models to monitor and valuate various refining scenarios, including different Natural Gas, O2, C, Lime Injection & Electrical Power Profiles.
Benefits are increased productivity; yield; while reducing tap alloy addition; Power on Time; and process variability.
- Dynamic Control & Optimization during Melting & Refining
- Reduced Tap Alloy Additions
- Reduced Tap-to-Tap Time
- Increased productivity
Value for Money
- Electrical Energy Savings
- Fuel Savings
- Reduced Power On Time
- Increased Yield
- Reduced Emissions
- Environmental sustainability
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