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ANALYTICAL MODEL FOR DUST EMISSION DURING CHARGING PHASE OF

ELETRIC ARC FURNACE

Article · December 2016

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 ANALYTICAL MODEL FOR DUST EMISSION
DURING CHARGING PHASE OF ELETRIC ARC
FURNACE.
Abstract: The scope of the work is to
implement an analytical model to evaluate the
efficiency of dust particle capture during the
charging of an electric arc furnace. At first we
introduce the factors which influence the
emission of dust during charging phase of the
EAF (Electric Arc Furnace) and we complete
creating a connection of the hot thermal
plumes models of Kuei-Hung and Hemeon
with our model. Stabilizing an approach to
evaluate the efficiency of dust capture by a
canopy hood placed at the roof of the plant
basing ourselves on the fluid-dynamic theory
of particles. At the end we compare the results
obtained of the efficiency analytically with the
efficiency obtained using CFD simulations
setting the same boundary conditions.
DUST EMISSION CONTROL FROM
ELECTRIC ARC FURNACE DURING
CHARGING PHASE.
Abstract: The aim of the work is to introduce
an analytic model to estimate the quantity of
dust that can be captured by a designed canopy
hood. In the first place, we fixed the geometry,
the capacity of the furnace and the volume of
the crane. The Kuei-Hung is used to estimate
the velocity of hot air which is related to the
velocity of the dust particles. Fixing the
diameter of dust particles, and distributing the
size of the particles using the Rosin Rammler
.At last the capturing efficiency of dust
particles is estimated varying the flow rates of
the canopy hood.
Yves D. Tiwa*
Mechanical Engineer
10.12.2016
1. INTRODUTION
The control of fumes dispersion is a
relevant problem to reduce the emissions
in the plant internal environment. The
emissions are divided by primary
emissions when the roof of the furnace is
closed (electric arc fusion-melting phase)
and secondary emissions (charging phase
of the furnace) with opened roof of the
furnace. Primary emissions are those that
are produced during the EAF (Electric arc
Furnace) melting and refining process with
the roof of the EAF closed. The DES
(Direct Emission System) collects the
greatest percentage of EAF emissions
through a pipe called Fourth hole. This
operation is done only when the furnace is
in a horizontal position [3]. The efficiency
of the plant is mainly related to the amount
of depression in the furnace. The
secondary emissions are exhausted through
a canopy hood placed at the roof of the
plant with an exhaustion fan downstream.
Secondary emissions (fumes and dust
particles) are released during the charging
of the furnace with scrap.
The goal of the work is to implement an
analytical model based on fluid-dynamics
and particle diffusion theory to evaluate
the efficiency of dust capturing by a
conventional canopy hood designed using
the Kuei-Hung model. Through CFD
simulations implemented using the same
boundary conditions as the analytical
model, we compare the efficiencies
obtained.
 (2)
2. KUEI-HUNG MODEL
The dimension of the thermal plume released The velocity of fumes ], at the same
during charging of the furnace increases height ;
during the ascending motion of fumes due to
the entrainment of air from the outside
atmosphere. The fume temperature decreases,
the thrust determines the velocity of the
thermal plume [1]. The Kuei-Hung Model Cross sectional of the heat source
determines theoretically the dimensions of the Temperature difference between heat
thermal plumes and average velocity of fumes source and environment
during the charging phase of the furnace [4]. Industries estimate the
Considering Figure 1 which represents the
thermal plume, generated by a source of finite Volumetric flow rate of fumes
dimension of conical form. The thermal plume arriving at the canopy hood.
generated has the same form as a thermal
plume generated by a point source.
Considering Figure 1 which represents the
thermal plume, generated by a source of finite
dimension of conical form. The thermal plume The volumetric flow rate extracted by the
generated has the same form as a thermal canopy hood is greater because of the space
plume generated by a point source; oscillations of the thermal plume; the width is
fixed and increased by increasing the diameter
𝐷𝑓 of fumes at h.

Theoretical flow rate that must be capture the

hood is the sum of the flow rate of fumes
emitted and flow rate of the entrained air
h

with fumes through cross sectional area of

Thermal
aspiration.
plume
𝑥𝑓

Emitting surface ( )

EAF : Velocity of the entrained air = 0.5m/s.

Can be reduced proportionally to the volume
Z

of the hood V, this to take into account the

effects of gas accumulation.
Ds

Is the reduction factor: 0 ÷ 3. If = 3, is

Figure 1: Theory representation of thermal
the limit that guarantee max performances of
plume by Kuei-Hung
the aspiration system.
The diameter [mm] of the thermal plume at
a distance h [mm] from the furnace;
(1)
Height of thermal plume respect
: Source emission diameter
Virtual point source.
 3. ROSIN RAMMLER
DISTRIBUTION
The Rosin Rammler distribution predicts the
mass fraction of particles having size greater
than a certain fixed diameter The Rosin
Rammler distribution is an application of the
Weibull distribution to describe size particle
distributions. The stochastic Rosin-Rammler
diameter distribution is given by a mass
fraction of particles:
( )
( )
is the parameter which influences the mean
particle size of distribution. It can be seen as
the mean particle diameter of the particles.
Where
Your particle size distribution may be defined
most easily by fitting the size distribution data
to the Rosin-Rammler equation. In this
approach, the complete range of particle sizes
is divided into a set of discrete size ranges,
each to be defined by a single stream that is
part of the group.
The Rosin Rammler distribution is used by
CFD software like Ansys Fluent to track
particles.
4. METHODOLOGY
4.1 AIM
The aim of the work is to implement an
analytic approach of the canopy hood dust
capture efficiency instead of CFD modelling.
The essence of the analytical model is to
reduce the time and resources for companies to
determine the capture performances of the
canopy hood.
Based on the dimensions of the furnace, the
capacity of the furnace, the Kuei-Hung model
is used to design the canopy hood.
4.2 PROCEDURE
Referring on to Figure (2) below, the aim
of a canopy hood is to capture dust
particles and absorb fumes. To evaluate
the capturing efficiency of a hood, we have
to know the quantity of dust captured per
unit of time. The estimation of the average
mass of dust expelled by the furnace
during charging is important. There are 3
methods to know the average density of
dust.
 Mass loading type: samples of
dust particles from filter or bag
house or the surrounding EAF
are absorb and weight.
 Relative loading: Scattering
light principle with lasers.
In the study, the mass loading type is used
based on the particles collected from the
filter during charging process. Considering
that the plume develops is free
atmosphere, there are 2 two mechanisms
for fumes and dust generation:
 Combustion: generates fumes
and low quantity of dust due to
high enthalpy or heat loss.
 Mechanical brusque collision in
of scrap in a high enthalpy
content molten bath: this
generates the highest quantity
of dust. So the studies are based
on this second point of view.
The following dimensions and parameters are
taken into consideration to construct the model
are resumed in Table 1. The charging time,
furnace-crane dimensions and designed flow
rate are obtained from [1][2]. The dust particle
size interval (diameter) is estimated referring
to [5].
 𝑑𝑐𝑟𝑎𝑛𝑒

𝑐𝑟 CRANE

X/2 s
𝑣𝑠𝑐 /2
𝑐𝑟𝑎𝑛𝑒

𝑣𝑒𝑚 𝐻𝐸𝐴𝐹
EAF 𝑣𝑠𝑐

Figure 2: Schematic representation of dust escape

Parameter Symbol Value Steps 1 and 2 are the similar for both part I and
Furnace Emitting D 5m II. Step 3 of part I is used as an initial
surface Diameter condition to resolve step 3 of part II.
Particle size
interval
Step 2 Step 3 (I)
Distance furnace- H 15m
Hood
Furnace height 1.5D
Distance between 0.1D Part I Part II
crane opening and
furnace
Crane opening 0.6D
Step 1 Step 3 (II)
diameter
Charge Time 7secs
Referent particle 25mg/
density Figure 3: Work Organization

Table 1: Input parameters for analytical model I. RELEASE WITH HOOD

ABSENT
The phenomenon is divided into two parts: STEP 1:
I. Release with Canopy Hood  The scrap falls due to gravity
ABSENT. from the crane. Linear velocity
II. Release WITH Canopy Hood variation of dropping scrap:
PRESENT. is the estimated velocity of
The model is divided into 3 steps:
scrap at the bottom of the
STEP 1: Analysis Crane-Furnace.
furnace.
STEP 2: Kuei-Hung Model.
STEP 3: Dust Analysis Furnace-Hood. )
The difference in volume between the
furnace and crane-molten bath [6] permits
to estimate the maximum amount of dust
emitted by the furnace assuming the
furnace and crane are cylindrical. The
molten steel bath is assumed to have a
spherical conical shape.
Assuming the dust particles have a
uniform spherical form then the average
maximum number of particles released in a
second is:
̅̅̅̅
( )
Where ̅̅̅̅ is the average diameter of dust
particles interval the flow rate of particles
emitted from the bath and the emission
velocity are determined from and
(area of molten bath).
Where are the radius part and
height of the conical part. is the radius of
the molten bath (spherical part).
The average reference mass permits to
estimate the density of each particle per size.
( )
STEP 2:
Using equation (4) from the Kuei-Hung to
derive the velocity of fumes at varying
distance from the emitting surface of the
furnace; the fume velocity is related to the
differential equation which permits the dust
analysis.
STEP 3 PART I:
The velocity at s=0 and s=H (Figure2) can
be simulated using the Euler-Lagrange
Random Walk model for dust particles
assuming the particles when released take
a vertical pathway to the hood.
Obtaining the following equations by
integrating the Euler equation by
neglecting (force due to
pressure change and gravity) and only the
drag force is left due to the high impulsive
upward motion of the particle when
released. The action of gravity is
determined by the terminal velocity of
each particle.
( )
The velocity of the fluid (air) u= velocity
of fumes from Kuei.
| |
Integrating we obtain:
(
The terminal velocity is given by:
 ( )
( ) is the estimated exhaustion time
The necessary average velocity between part I
and II is given by:

Corresponding distance from the furnace

emitting surface
HOOD EFFICIENCY DETERMINATION
The efficiency is determined by applying the
II. RELEASE WITH CANOPY Rosin Rammler distribution. The application
HOOD PRESENT of the Rosin Rammler is divided into two:
STEP 3 PART II: - At first the distribution in equation (9)
The presence of an exhaust canopy hood is used to estimate the mass fraction of
creates a depression at its entrance. The the particles for every particle
depression accelerates the dust particles diameter from .
thereby reducing the influence of gravity. - Applying equation (29) on the Rosin
Assuming that all particles having the average Rammler of equation (9), by
velocity between the PART I and II to be determining in function of ,a
greater than their terminal velocity are been comparison of mass fraction can be
captured by the canopy hood. established between the emitting
At hood inlet only (force due to pressure surface of the furnace and the hood
gradients) acts on the dust particles and in inlet.
literature, the depression curve along the inlet Distribution at EAF Emitting Surface
of the canopy hood describes a polynomial Assuming initially that the spread
from 2nd – 4th grade depending on the parameter from equation (9)
geometric configuration of the hood. and ̅̅̅̅. Then an initial
Hypothesis of a 2nd grade polynomial that is a distribution is determined which permits to
parabola passing per three points. The greatest determine the exact values of the spread
depression is at the centre of the hood (point parameter and the Rosin Rammler
A) and the absolute value of depression diameter.
corresponds to the gauge pressure of the fan.
Points B and B’ are the extreme points of the
( )
hood with null depression. The diameter of the
hood is obtained from Kuei-Hung in equation The exact values of and are
(6).
given by:
Then: ( ) ( )
( ( ))
Parabola of equation:
( )

( )

From (velocity at distance H part I) the The distribution of diameter at EAF

increase in velocity of dust particles during furnace release surface is given by:
exhaustion is represented as follows;
(28) ( )
Distribution at Hood Inlet
Before implementing the distribution, it is
important to determine the limit diameter
of particles with greater than the
terminal velocity. These are the particles
captured by the hood. Then the
distribution at hood inlet is based on .
(̅̅̅̅̅̅)

̅̅̅̅̅ Average velocity of captured dust

particles.
The efficiency of the hood is given by the
Figure 4: Dust particle velocities at hood inlet and
ratio between the sums of the mass
terminal velocity
fraction of particles at hood inlet and the
furnace emitting surface.
∑ Figure 5: Represents the distance
∑ attained by the dust particles from the
furnace emitting surface. This figure
4.3 RESULTS describes significantly the previous
Using the input data in Table 1 and figure by showing exactly the interval
applying the above model, the of size of dust particles capable of
following results are obtained based on being captured.
figures 4,5,6,7.
Figure 4: Represents the velocity of
dust particles at H=15m meters from
the furnace emitting surface. The
curves represent situations whereby:
- The hood is absent (Blue)
corresponding to Part I,
characterized by a small difference
in velocity between dust particles.
- The presence of the hood (black
curve) describes the increase in
velocity of particles due to
exhaustion (Part II). The red curve
corresponds to the average
between velocity of Part I and II. Figure 5: Distance attained by dust particles from
The terminal velocity curve permits furnace emitting surface
to stabilize which interval of size of Figures 6 and 7 represent the mass
particles are being captured. fraction distribution of particles at
Observing the point of intersection furnace emitting surface and at the
between the green curve and the red of hood inlet respectively using the Rosin
we quickly conclude that the Rammler distribution. From Figure 6
interval of size of dust particles more particles of greater size are being
captured is diameter. released but from figure 7 most
 particles of smaller size and weight are Figure 8 represents the particle
being captured by the hood. This trajectory using the CFD with the same
permits to understand the value of the dimension of canopy hood.
hood capturing efficiency.

Figure 8: CFD representation of particle trajectory

with their corresponding velocity variation [m/s]

Figure 6: Particle Mass fraction distribution at  Observing Figure 8 the velocity

furnace emitting surface
at hood inlet ranges from 8.8-
14.5m/s and in the case of the
model based on Figure 5 in the
case “Hood Present” ranges
from 6.5-14.1m/s.
 Table 2 below represents the
efficiency parameters and
values of both CFD and model.
CFD
N°Particle tracked 800
N° captured 380
0.48

Figure 7: Particle Mass fraction distribution at

Model
hood “Present” inlet

Comparing the efficiency-velocity Mass fraction at 50.75

obtained from a CFD simulation using furnace
the same boundary conditions with Mass fraction 23.40
Fluent (Euler Model and Rosin captured
Rammler) and the efficiency-velocity 0.46
obtained using the model.
Table 2: CFD and Model Efficiency and
Parameters

4.4 CONCLUSIONS
Based on Table 2 and the results obtained
from the model and the CFD, we can
conclude that the analytical model is a
useful instrument to evaluate the efficiency
of any conventional hood.
Department of Industrial and Prod.
Engineering, University of Ibadan,
Nigeria, Department of Mechanical
Engineering, The Polytechnic, Ibadan,
Nigeria, May 2007.

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[4] M. Campolo, L. Scarbolo, A. Soldati,

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