Article
Energy & Fuels
Alessandro Cardarelli, Michele De Santis, Filippo Cirilli, Marco Barbanera
Summary: The most urgent concern for the steel industry is climate change. This study investigated the use of biochar as a substitute for fossil coal in the EAF steelmaking process and developed a CFD model to analyze the combustion reaction.
Article
Energy & Fuels
Lina Kieush, Johannes Schenk, Andrii Koveria, Andrii Hrubiak, Horst Hopfinger, Heng Zheng
Summary: The influence of different carbon sources on slag foaming behavior was studied, and the effect was evaluated using various methods. Biochar showed inferior foaming characteristics compared to other carbon sources. However, when a mixture of coke and biochar was used, the slag foaming process improved and showed similar characteristics to conventional carbon sources. Differences in the presence of crystalline phases were observed in the slag foam, and a layer between the foam slag and the crucible wall was found in many samples.
Article
Energy & Fuels
Alessandro Cardarelli, Marco Barbanera
Summary: The iron and steel industry is highly energy-intensive and emits a large amount of CO2. This study shows that substituting fossil coal with pulverized hydrochar can reduce CO2 emissions in the steelmaking process. The environmental impacts of using hydrochar and its manufacturing process were comprehensively assessed.
Article
Green & Sustainable Science & Technology
Mamdouh Omran, Timo Fabritius, Yaowei Yu, Eetu-Pekka Heikkinen, Guo Chen, Yilmaz Kacar
Summary: This study found that microwave heating significantly improved zinc recovery rates from EAF and CRC dusts compared to conventional thermal heating, requiring lower temperatures. This indicates that microwave heating is an effective method for enhancing metal recovery efficiency.
JOURNAL OF SUSTAINABLE METALLURGY
(2021)
Article
Materials Science, Multidisciplinary
Christopher DiGiovanni, Delin Li, Ka Wing Ng, Xianai Huang
Summary: The electric arc furnace (EAF) has the potential to contribute to decarbonization of the iron and steel industry. To initiate slag foaming, carbon needs to be injected into the molten slag during EAF steelmaking. Biocarbon has gained attention as an alternative carbon agent. This study measured the slag foaming height when two biochar candidates were added to the molten slag layer and compared them to fossil carbon candidates.
Article
Green & Sustainable Science & Technology
Lingzhi Yang, Hang Hu, Sheng Yang, Shuai Wang, Feng Chen, Yufeng Guo
Summary: The electric arc furnace (EAF) steelmaking process is an important method for recycling scrap resources and achieving sustainable development in the iron and steel industry. This paper comprehensively analyzes and quantifies the life cycle carbon footprint (CF) of EAF steelmaking process under 13 different smelting modes. The results show that reducing the hot metal ratio or indirect CF of hot metal production can significantly decrease the total CF of EAF steelmaking process. The adoption of full scrap smelting mode with appropriate amount of carbon powder and natural gas, or the use of clean energy power production and low-carbon materials, is recommended for future EAF steelmaking process.
SUSTAINABLE MATERIALS AND TECHNOLOGIES
(2023)
Article
Green & Sustainable Science & Technology
Bohan Tian, Guangsheng Wei, Xin Li, Rong Zhu, Hao Bai, Weijian Tian, Kai Dong
Summary: This study analyzed the economic and environmental indices of electric arc furnaces with hot metal charging in China. The results showed that a 50% hot metal ratio can achieve a good balance between economic and environmental performance, making it more advantageous compared to other processes.
JOURNAL OF CLEANER PRODUCTION
(2022)
Article
Computer Science, Artificial Intelligence
Maciej Klimas, Dariusz Grabowski
Summary: This paper proposes an approach to EAF modeling based on a deterministic differential equation enhanced with stochastic ingredients. The identification of time series representing equation coefficients is conducted using a genetic algorithm. The results indicate that the LSTM model outperforms chaotic or stochastic models in different stages of the EAF work cycle.
APPLIED SOFT COMPUTING
(2023)
Article
Green & Sustainable Science & Technology
Lingzhi Yang, Hang Hu, Mengxian Wang, Feng Chen, Shuai Wang, Yufeng Guo, Sheng Yang, Tao Jiang
Summary: This paper introduces an EAF steelmaking process driven by a solar energy system, which reduces dependence on traditional energy sources and offers environmental and energy-saving advantages. The research findings show that EAF-SES has a lower life cycle carbon footprint but higher production costs compared to EAF-TES. When the electricity price is low or the carbon tax is high, EAF-SES has significant economic and environmental benefits.
JOURNAL OF CLEANER PRODUCTION
(2023)
Article
Engineering, Electrical & Electronic
Zahra Babaei, Haidar Samet, Masoud Jalil
Summary: This paper proposes new models based on the instantaneous EAF voltage and current to model the highly time-varying and nonlinear behavior of electric arc furnaces. Modified versions of the Schwarz model are introduced to consider the time-varying nature of arc parameters. The accuracy of the proposed models is evaluated by calculating various performance indicators, and MATLAB codes are provided for generating the model parameters time series.
IET GENERATION TRANSMISSION & DISTRIBUTION
(2023)
Article
Materials Science, Ceramics
Min Kyo Oh, Joo Hyun Park
Summary: The study investigated the interfacial reaction between CaO-SiO2-FeO-Al2O3-MnO-MgO-xCaF2 type electric arc furnace steelmaking slag and magnesia refractory. It was found that the CaF2 content in the slag affects the thickness of the solid solution layer, and by varying the MgO content in the slag, the depth of refractory dissolution and slag penetration were determined. The study also proposed a critical CaF2 content of approximately 3 wt% that had no significant effect on refractory corrosion.
CERAMICS INTERNATIONAL
(2021)
Article
Materials Science, Ceramics
Bohan Tian, Yun Zhou, Guangsheng Wei, Rong Zhu, Wenhe Wu, Lingzhi Yang
Summary: Bottom-blowing is an effective metallurgical method in EAF steelmaking, using scrap as the primary raw material with lower carbon emissions. This study investigates the influence of different CO2 ratios on pore distribution and microstructure through oxidation experiments on bottom-blowing elements.
CERAMICS INTERNATIONAL
(2022)
Article
Thermodynamics
Feng Li, Mansheng Chu, Jue Tang, Zhenggen Liu, Zichuan Zhao, Peijun Liu, Ruijun Yan
Summary: This research analyzes and evaluates the energy-saving potential and environmental benefits of two hydrogen-based steelmaking processes, finding that they can significantly reduce energy consumption and CO2 emissions compared to traditional blast furnace-basic oxygen furnace process. The study also evaluates the future potential of the HSE process and identifies the use of renewable electricity as a way to reduce carbon emissions.
APPLIED THERMAL ENGINEERING
(2022)
Article
Engineering, Electrical & Electronic
Markus Dietz, Dariusz Grabowski, Maciej Klimas, Hans-Joerg Starkloff
Summary: This paper models the electric arc furnace (EAF) using a random differential equation and estimates the model coefficients based on measurement data. The study shows that the coefficients can be iteratively estimated using a Monte Carlo method and a genetic algorithm applied to the input signal. Solutions are validated using statistical tests.
IEEE TRANSACTIONS ON POWER DELIVERY
(2022)
Article
Environmental Sciences
Michael Mensah, Avimanyu Das
Summary: Valuable metals were successfully recovered from EAF slag through a smelt-reduction process, generating pig iron with high carbon content and a depleted slag. Optimal process conditions were determined using experimental design and response surface methodology, resulting in significant recovery of valuable metals.
ENVIRONMENTAL TECHNOLOGY
(2023)
Article
Materials Science, Multidisciplinary
Thomas Hay, Alexander Reimann, Thomas Echterhof
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2019)
Article
Materials Science, Multidisciplinary
H. Pauna, T. Willms, M. Aula, T. Echterhof, M. Huttula, T. Fabritius
METALLURGICAL AND MATERIALS TRANSACTIONS B-PROCESS METALLURGY AND MATERIALS PROCESSING SCIENCE
(2020)
Article
Metallurgy & Metallurgical Engineering
Thomas Hay, Jesus Hernandez, Suzanne Roberts, Thomas Echterhof
Summary: The accurate calculation of view factors is crucial for electric arc furnace process models, and simplifying assumptions are necessary for computational efficiency. Two new calculation methods presented in this study reduce assumptions, are validated to be accurate, and are suitable for online applications and process optimization models.
STEEL RESEARCH INTERNATIONAL
(2021)
Review
Metallurgy & Metallurgical Engineering
Thomas Hay, Ville-Valtteri Visuri, Matti Aula, Thomas Echterhof
Summary: This article reviews mathematical process models for electric arc furnaces used in scrap-based steelmaking, examining common modeling approaches and descriptions of main phenomena. It also discusses the validation of these models and suggests further development for mathematical process models.
STEEL RESEARCH INTERNATIONAL
(2021)
Article
Chemistry, Multidisciplinary
Thomas Willms, Thomas Echterhof, Stefan Steinlechner, Matti Aula, Ahmed Abdelrahim, Timo Fabritius, Davide Mombelli, Carlo Mapelli, Stefan Preiss
APPLIED SCIENCES-BASEL
(2020)
Article
Engineering, Chemical
Marcus Kirschen, Thomas Hay, Thomas Echterhof
Summary: Steelmaking based on direct reduced iron offers a lower CO2 emission alternative to traditional blast furnace production, with DRI being melted and refined in electric arc furnaces under different conditions. Data and analysis of slag composition in 16 EAFs are provided to optimize slag operation and improve the DRI melting process in EAFs.
Article
Thermodynamics
N. Schmitz, L. Sankowski, F. Kaiser, C. Schwotzer, T. Echterhof, H. Pfeifer
Summary: The aim is to move away from fossil fuels by massively reducing CO2 emissions. Options for CO2-free technologies in the steel hot rolling process are discussed, highlighting the impact on CO2 emissions. Each alternative has significant potential to save CO2 emissions depending on the electricity generation mix and renewable energy sources.
Article
Materials Science, Multidisciplinary
Alexander Reimann, Thomas Hay, Thomas Echterhof, Marcus Kirschen, Herbert Pfeifer
Summary: This study investigates the applicability of three different statistical modeling approaches for predicting the electric energy demand of EAF, using more than 21,000 heats from five industrial-size EAFs. The results show that Gaussian process regression (GPR) offers the best overall accuracy, but the benefit of applying nonlinear models varies between the investigated furnaces. Possible reasons for the inconsistent performance of the methods are discussed.
Article
Materials Science, Multidisciplinary
Christian Schubert, Dominik Bueschgens, Moritz Eickhoff, Thomas Echterhof, Herbert Pfeifer
Summary: Improving overall energy efficiency is essential for reducing costs, lowering energy consumption, and decreasing emissions contributing to climate change. Using off-gas to preheat metal scrap in metallurgical recycling processes can significantly enhance energy efficiency, although it requires precise planning and process control. In this study, a simplified model for a scrap preheating system in the steel processing industry is presented, aiming to improve process control and design of preheating devices in metal recycling processes.
Article
Metallurgy & Metallurgical Engineering
Ahmed Abdelrahim, Matti Aula, Mikko Iljana, Thomas Willms, Thomas Echterhof, Stefan Steinlechner, Davide Mombelli, Carlo Mapelli, Mamdouh Omran, Stefan Preiss, Timo Fabritius
Summary: After tests and research, two briquettes are found suitable for EAF use, three are deemed unsuitable, and two are considered to have limited application.
STEEL RESEARCH INTERNATIONAL
(2022)
Editorial Material
Materials Science, Multidisciplinary
Thomas Echterhof, Ko-Ichiro Ohno, Ville-Valtteri Visuri
Article
Metallurgy & Metallurgical Engineering
Davide Mombelli, Matteo Quadrio, Carlo Mapelli, Thomas Echterhof, Leixuri Fernandez Aparicio, Christoph Sorger, Thomas Griessacher, Dirk Mudersbach, Susanne Schueler
Summary: The Fines2EAF project aims to increase the value of Electric Arc Furnace steelmaking residues by recycling and reusing them in the form of cement-free briquettes. Industrial trials have shown that these briquettes have similar properties to traditional slag, with limited differences. The project has also confirmed that the recirculation of fines has a negligible or potentially positive impact on the environment.
ISIJ INTERNATIONAL
(2022)
Review
Materials Science, Multidisciplinary
Lina Kieush, Johannes Rieger, Johannes Schenk, Carlo Brondi, Davide Rovelli, Thomas Echterhof, Filippo Cirilli, Christoph Thaler, Nils Jaeger, Delphine Snaet, Klaus Peters, Valentina Colla
Summary: This review emphasizes the significance of using secondary carbon bio-carriers in iron and steel production, focusing on the application of torrefied biomass in various metallurgical processes and outlining the material requirements and pathways for their use. The most promising ways to utilize secondary carbon bio-carriers are identified in scrap/EAF, DRI/EAF, SR/BOF, and SAF.
Proceedings Paper
Automation & Control Systems
H. Pauna, M. Aula, T. Willms, T. Echterhof, M. Huttula, T. Fabritius
Summary: This paper discusses the application of optical emission spectroscopy (OES) in the steel industry to achieve the goal of reducing CO2 emissions. The potential of OES as an on-line data acquisition method is explored through the introduction of new processes, practices, sources of data, and digitalization together with automation.