ArcSpec system
Unlocking efficiency in electric arc furnace operations with ArcSpec
Steelmaking via Electric Arc Furnace (EAF) is an energy-intensive process, further complicated by high production volumes and significant variability in raw materials and operating conditions. These factors make EAF operations both complex and costly.
One of the greatest challenges in optimizing the EAF process has been the lack of real-time data and limited process visibility. Extreme furnace conditions—such as intense heat and slag spray—render conventional measurement methods ineffective, leading to inefficiencies including excessive energy consumption, accelerated equipment wear, and production delays.
Until now.
Leveraging our patented technologies, we have developed ArcSpec, a groundbreaking process control system that provides real-time insight into furnace operations. ArcSpec enables continuous measurement, control, and optimization of the EAF process, helping operators reduce operating costs, improve productivity, and extend equipment life.
For the first time, it’s possible to see inside the furnace and take action instantly.
Real-time dynamic control of EAF process leads to
Energy efficiency
3-8 % Reduction in power consumption
Increased capacity
5-8 % Production increase
High return of investment
Typically 3-4 months payback period
Optimize the Electric Arc Furnace process
An EAF generates large amounts of light from multiple sources. The arc, flames, and hot slag inside the furnace all emit light. ArcSpec measures these light sources in real-time using Optical Emission Spectroscopy (OES). The spectrum of light provides data about the melting process and the source of the light.
ArcSpec further analyzes the data from EAF into control signals. These signals are sent to the furnace control system to make necessary adjustments that optimize the process. It determines when to start the different phases of the process and how to manage the process parameters. The collected and processed data is stored and made available to the customer for potential future data acquisition for machine learning purposes.
The increased availability of real-time data, combined with data-driven process optimization, reduces tap-to-tap times and enhances energy efficiency.
ArcSpec collects light from the EAF
The system breaks the light into spectral components
ArcSpec analyzes the data and generates control signals
The process is adjusted based on the signals
ArcSpec modules
In addition to the ability to see into the process, the system enables various controlling applications for the EAF process to serve the needs of different kinds of furnaces. We offer these control applications as control modules. With these control modules, we ensure that every delivered system is customized to match the needs of the furnace.
MONITOR sensor module
PRODUCTIVITY control module
EFFICIENCY control module
BASKET control module
BURNER control module
Future development
MONITOR sensor module
Monitor the progress of scrap melting
The MONITOR sensor module is used to monitor the progress of scrap melting. It supports the decision-making process of the operators by providing them with measured scrap melting progress information. No control actions are performed.
PRODUCTIVITY control module
Use higher voltage taps longer safely to decrease tap-to-tap times
The PRODUCTIVITY control module monitors the arc visibility and scrap melting to time electrode voltage tap changes. For example, in stainless steelmaking voltage taps are lowered when the scrap protecting the sides of the furnace has molten.
By measuring scrap melting, it is possible to time the voltage tap decrease more accurately. This enables the use of higher voltage taps for a longer time. Optimized use of the electric current decreases the tap-to-tap times. This results in increased productivity without an increase in refractory wear.
EFFICIENCY control module
Use higher electrode voltages and lower current safely to decrease electrode consumption
The EFFICIENCY control module adjusts the electrical setpoints of the electrodes to achieve a longer arc, which corresponds to a higher voltage and lower current. This information is sent to the furnace automation system. The goal is to operate as close to the optimum power factor as possible.
Often this approach leads to a slightly longer tap-to-tap time but decreases electricity and electrode consumption. The damaging effect of the longer arc is mitigated by closely monitoring the measured light intensity levels. Upon increasing light levels, the voltage tap is automatically decreased. Alternatively, the electric setpoint of individual electrodes may be reset to the normal value, shortening the arc.
BASKET control module
Time the metal scrap charges as soon as safely possible
The BASKET control module monitors the progress of scrap melting in real-time to determine the optimal moment for additional scrap charges. The additional baskets should be charged as soon as they fit safely into the furnace. Too early charging will cause overfilling of EAF, whereas late-charging decreases furnace productivity and electric efficiency.
By measuring scrap melting, the scrap basket can be charged earlier on average. Optimal timing leads to faster tap-to-tap times and increased energy efficiency.
The system will give a message to the operator when the scrap basket should be charged. If basket volume information is available, the optimal moment of charging can be determined based on the scrap volume. If this information is not available, the system can give conditional commands to the operator. The message can be shown on the ArcSpec user interface or the factory’s own display via the automation system.
BURNER control module
Time burner operations
The BURNER control module controls burner operations with direct light information. The heating efficiency of burners decreases as meltdown proceeds. Operation with a low efficiency causes the energy of the burners to go into the furnace atmosphere rather than the scrap.
The drop in efficiency can be detected as an increase in the measured light intensity near the burner. The system shuts off the burner if it detects a drop in efficiency. Each burner can be controlled individually based on the measurements performed in that area. Optimal burner operation will improve the heating efficiency and provide savings in natural gas consumption.
Future development of ArcSpec modules
Luxmet is committed to developing the ArcSpec system. This means more functionalities and possibilities for our customers to benefit from the Optical Emission Spectrometry technology.
The technology enables real-time measurements of temperatures inside the furnace and the lights spectrum contains data about chemical elements reacting. These features enable notable possibilities for future development and our customers.
We offer everything as a service
We offer the ArcSpec system also as a turnkey service. Our services can consist of an assessment period prior to any final decision. All our products can be offered as a continuous service, including the use and maintenance of the system.
Interested to learn more about the different measuring methods for the Electric Arc Furnace?
We created a guide based on years of research to clarify what are the different methods for measuring the Electric Arc Furnace process and what are they good for.
Do you want to know more?
By filling this form you agree to the privacy policy. You can unsubscribe at any time.