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The Comparative Analysis of Electrode Control Systems of Electric Arc

Furnaces and Ladle Furnaces

Conference Paper · May 2016

DOI: 10.1109/ICIEAM.2016.7910888

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 2016 2nd International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)

The Comparative Analysis of Electrode Control

Systems of Electric Arc Furnaces and Ladle Furnaces
Nikolaev A.A., Tulupov P.G., Astashova G.V.
Automated Electrical Drive and Mechatronics Dept.
Nosov Magnitogorsk State Technical University
Magnitogorsk, Russian Federation
alexniko@inbox.ru, tulupov.pg@mail.ru

Abstract—The article presents the comparative analysis of

electrode control systems of electric arc furnaces and ladle fur-
naces illustrated by example of ARCOS (Siemens VAI, Primetals
Technologies), HIREG (Danieli), EMPERE (Amec Spie) and
DECTEQ (Ferrotron). The functional scheme for the following
systems presented offers the main algorithms of electrode regulat-
ing. Main advantages and disadvantages are mentioned below.
Besides, in the frames of our study, the authors present description
of the Russian system of electric mode control ASEMC RADUGA
NPA LF having a number of advantages in comparison to foreign
models.
Keywords—electrometallurgy; electric arc furnace; ladle fur-
nace; electrode; electric arc; electrode control system; arc ignition
I. INTRODUCTION
Nowadays the production of liquid steel in high productive
electric arc furnaces (EAF) with following extra furnace
treatment in ladle furnace (LF) is widespread in metallurgical
branch. Therefore, the following fact is justified by
economical and energy saving effectiveness of this electric
technological equipment. The most important part of EAF and
LF is electric mode control system, comprising electrode
control system[1,2,10-15].
In most of the cases, this system is delivered in the unit of
the main devices. The systems ARCOS (Siemens VAI,
Primetals Technologies) и HIREG (Danieli) are most well
known. The systems DECTEQ (Ferrotron, Germany) and
E.M.P.E.R.E. (Spie, France) are less known than above
mentioned. Thus, European manufacturers develop all the
modern electric mode control systems. According to the
tendency of import substitution in last decades in all the
branches of Russian economics, the team of scientists from
Nosov Magnitogotsk State Technical University
(Magnitogorsk, Russia) has carried out and implemented
native system of electric mode control for EAF and LF, which
was named ASEMC «RADUGA NPA LF».
The comparative analysis of the most widespread control
systems distinguishing the main advantages and disadvantages
is not presented enough in foreign and Russian professional
and scientific magazines. Such analysis will allow us to reveal
the prior vector of scientific investigation in this field, and to
highlight the priority of native electric mode control system
use, in comparison to other analogues.
II. ELECTRIC MODE CONTROL SYSTEM ARCOS
The system of electric mode control ARCOS (Siemens
VAI, Primetals Technologies) has two level structure (fig.1),
as the most number of the similar systems. At the second level
the number of operating curve and tap reference is formed for
furnace transformer and reactor according to the heat profile.
The transition criterion from one heating stage to another is
the indicator of specific power consumption. At the first level,
comprising the electrode control system there is a process of
signal step by step forming reference signal for servo valve.
Initially, the feedback signals are conducted to electric
parameters measuring block of EAF. According to the phase
voltage and electric arc current feedback signals, on its
background may be calculated phase impedance ZACT as:
U 2 ph
Z ACT = = const , (1)
I ARC
where U2ph is the phase voltage measured between the
terminals of the secondary winding of the furnace transformer
and the furnace bottom; IARC is the electric arc current.
The signal of regulating error ∆Z is defined on the base of
calculated real meaning of impedance, and the impedance of
reference, formed in the output of set point value storage
block. Further, the meaning of regulating error conduct to the
input of regulator, having proportional-integral structure. This
system foresees the probability of electric arc resistance and
voltage regulating, which is necessary at late heat stages to
support arc length at constant level according to the following
equations:
U ARC = RARC I ARC = const , (3)
U ARC
RARC = = const , (4)
I ARC
where U2ph is the phase voltage measured between the
terminals of the secondary winding of the furnace transformer
and the furnace bottom; IARC is the electric arc current, RARC
is the electric arc resistance.

978-1-5090-1322-7/16/$31.00 ©2016 IEEE

 2016 2nd International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)
From the measuring system of phase
To control system of EAF
voltages and electric arc currents at
ua,b,c ia,b,c hydraulic circuit
the secondary side of furnace
LEVEL №2 transformer LEVEL №1 UREFA,B,C

Heating profile A A
IRMS, I(n) Arc Compensation D
D SC modes
URMS, U35kV ignition of voltage
protection
PLC control fluctuations Ramp
Block of Z ACT. ABC function
W EAF electric Resonance Electric arc generator
parameters ZACT. A Foamed slag
behavior current
calculation measuring
S, P, Q, I, protection threshold
ZACT. B Limiting block
cosφ ...
ZACT. C Non-linear ΔVREG Ignition
u35kV
step W NTR NR NOC regulator
ZRef Z REF. A VIGN
1 100 17 5 1 NTR Noc _ k PI-REG +
Level NR Z + ΔZ + VREG
2 400 18 7 2 NR REF. B
2 ... N OC
NTR Z REF. C
... ... ... ... Vmanual
6 2500 17 4 6 NTR NOC Control signal switch
Set point value storage
Manual control block
block

Fig. 1. Simplified operational scheme of EAF electric mode control system ARCOS (Siemens VAI, Primetals Technologies).

1
ТI p

Fig. 2. Operational scheme of non-linear regulator in ARCOS control system.

It is important to note that proportional part of regulator is
non-linear (fig. 2). Therefore, each transformer and reactor
operating stage corresponds to the unique set of gain factors of
proportional part of regulator. It’s necessary to regulate
significant error meanings with great operating speed and for
linearization of non-linear characteristic of servo valve.
Besides, ramp function generator is used in output of regulator
designed for prevention of unstable electric arc mode of
burning, caused by elastic vibrations of the electrode arm as
mechanical element.
III. ELECTRODE CONTROL SYSTEM HIREG PLUS
A differential exponent is used as the regulating parameter
in the given control system(fig.3). It is calculated on the
following formula and let us to carry out indirect control of
EAF phase admittance:
Error=K −I 1K Iph I1 -K U U 2ph ,
where KI is the coefficient taken into account the change in the
transformation ratio of the furnace transformer, KIph is the
coefficient of phase balancing, I1 is the current of the high
voltage side of the furnace transformer (on condition that the
windings are connected as ∆/∆-0), KU is the coefficient
determined by the actual transformer tap, admittance setting,
the number of the operating curve and by the system of
dynamic compensation of voltage fluctuations in the supply
network[3] HIREG DEC, U2ph is the phase voltage measured
between the terminals of the secondary windings of the
furnace transformer and the furnace bottom. The functional
scheme on fig.4 describes the error forming algorithm in more
details.
The regulator in the system of HIREG also has
proportional-integral structure. In the HIREG system, in
difference from ARCOS, we have the division of electric and
hydraulic circuit. Therefore, with the help of non-linear block
(2) NB1 bordering of small, middle and significant meanings of
error is carried out with the reference of corresponding level
of operating speed for each of them. In addition, this block
 2016 2nd International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)

1
ТF p +1
1
TI p

Positive range(A)

Slope(0..B)
Slope (B..10000)
Slope(0..A)

Negative range(B)
Slope(A.10000)
Slope exp. A..B
Range 0..A
Range 0..B

Slope B..10000

Fig. 3. Simplified operational scheme of the EAF electrical mode control system HIREG (Danieli, Italy).

Fig. 4. Operational scheme of the error signal forming algorithm in HIREG system.

comprises the function of short circuit technological mode
protection. The adaptation of electrode speed to operating
stage of furnace transformer is performed with coefficient Ka.
As for hydraulic circuit, the linearization of servo valve in
this system is understood as achievement of symmetrical
characteristic relatively to origin of coordinates in range of
±30% of maximum reference signal. Linearization may be
executed only by linear function, that excepts the possibility of
compensation of servo valve gain properties in the range of
long shifts.
IV. ELECTRODE CONTROL SYSTEMS EMPERE AND DECTEQ
Electric mode control system EMPERE (Amec Spie,
France) comprises the structural components for the system to
work in modes similar to ARCOS (keeping the constant
impedance of phase Z2ph, arc voltage UARC and arc resistance
RARC). Two alternative operating modes are foreseen in this
system:
1) Keeping of electric arc power constant. In this case
electric arc power may not be used as regulating parameter
due to specifications of curve form of electric characteristic,
reflecting the dependence of arc power on arc current
PARC=f(IARC). The problem is that set point value PARC may be
obtained with two different meanings of IARC, that brings
indefiniteness into system.
2) Furnace operating mode with fuzzy regulator [5],
functioning on the principles of fuzzy logics. The use of this
mode allows adapting the regulating parameter set point
 2016 2nd International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)

Fig. 5. Operational scheme of the electric mode control system EMPERE (Amec Spie, France).

Fig. 6. Operational scheme of the electric mode control system DECTEQ (Ferrotron, Germany).

value automatically depending on real working condition. This
mode may be useful at the last heating stage if the slag
forming is not intensive enough. Therefore, in this case
changing of the set point value will help to prevent
overheating of water-cooled panels and to achieve full arc
covering by foamed slag.
On fig.5, we can see functional scheme of EMPERE
system. Its structure is similar to that of ARCOS and HIREG.
The most significant difference is regulator, working on the
principles of fuzzy logic. It is important to underline that the
structure of the given regulator is closed and consequently it
cannot be subjected to detailed analysis.
 2016 2nd International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)
The system DECTEQ (fig.6) is operating on the principles
similar to ARCOS and EMPERE systems. The process of
regulating may be done both by phase impedance and electric
arc current, It’s important that direct regulating of arc current
in the system causes a great doubt, because the studies having
been carried out before showed that this method is not
effective due to interaction of arc current in three phase EAF.
It may lead to stability loss.
In this system in difference from Hireg linearization of
servo valve is understood as its dead zone compensation. The
investigations show that dead zone in regulating characteristic
of servo valve leads to growing static regulating error. The
form of linearization curve is given and cannot be subjected to
correction that in its turn will not compensate the servo valve
gain properties in the range of significant shifts. For all that,
this system does not foresee any blocks to define system
operation speed in variable ranges of regulating error.
V. THE COMPARATIVE ANALYSIS OF FOREIGN ELECTRIC MODE
CONTROL SYSTEMS WITH CONTROL SYSTEM «RADUGA NPA LF»
On the background of performed analysis of the most
known EAF electric mode control systems we present the
comparative table, showing the main advantages and
disadvantages of each system (Table 1).
Thus, main problem may be highlighted in modern EAF
electric mode control systems: no linearization of electric and
hydraulic circuits. It allows to use no blocks of non-linear gain
(HIREG system), blocks of regulator non-linear proportional
part(ARCOS system), and to gain equal operating speed in the
whole range of electric arc length.
This technology was implemented into technological
production of Russian electric mode control system
“RADUGA NPA LF”. It was developed and put into operation
by joint efforts of NMSTU and JSC “KonsOM SKS”
(Magnitogorsk, Russia) research team.
The adaptive impedance regulator with 3-level structure is
in the background of the system. The linearization of electric
circuit is carried out at the first level, at the second – hydraulic
circuit; at the third is the compensation of scale coefficient and
electrical field strength. The linearization characteristics may
be changed by user without any limits. The formation of the
characteristic is performed on the base of mathematical model
of EAF electric and hydraulic circuits, which is described in
details in special literature.
Additionally it may be noted in most of modern EAF
electric mode control systems the transition from one heating
stage to another[7-9] is made on the base of specific power
consumption feedback. But this parameter is not directly
connected to heating stage, and because of it furnace
transformer and reactor switches may be done not in time. The
prior vector of “RADUGA” system development is the
argument of effectiveness and practical implementation of
diagnostic system of heating stage according electric arc
current and voltage signals harmonic composition.
TABLE I. ADVANTAGES AND DISADVANTAGES OF THE MOST KNOWN
ELECTRIC MODE CONTROL SYSTEMS
ARCOS (Siemens VAI, Primetals Technologies)
Advantages Disadvantages
1. Regulator structure defines 1. Combination of characteristics of elec-
different levels of operating tric and hydraulic circuit in one non-linear
speed for different meanings block
of regulating error 2. A great number of unique characteristics
2. The possibility of re- for each combination of furnace transform-
sistance and electric arc er and reactor taps in common with closed
voltage regulating at late
algorithms of definition non-linear block
stages of heat to keep con-
stant meaning of arc length parameters
HIREG (Danieli, Italy)
Advantages Disadvantages
1. Division of the control 1. Limited set of instruments for non-linear
blocks for electric and hy- characteristic correction
draulic circuits 2. Approach used in the system for lineari-
2. The possibility of manual zation does not provide servo vale dead
adjustment of system operat- zone compensation and its gain properties
ing speed for variable regu- in range of significant shifts.
lating error ranges
EMPERE (Amec Spie, France)
Advantages Disadvantages
1. Wide range of regulating 1. Closed linearization algorithms of ser-
parameters (phase impedance vovalve characteristic
Z2ph, electric arc resistance 2. The possibility of operating speed ad-
RARC, electric arc voltage justment in different regulation ranges is
UARC). missing
2.Use of intellectual forming 3. Fuzzy regulator structure is closed for
set point system, based on study and consequently it’s difficult
regulator, operating on the enough to evaluate its efficiency
principles of fuzzy logic
DECTEQ (Ferrotron, Germany)
Advantages Disadvantages
1. System structure is open, 1.The possibility of direct electric arc cur-
so it’s easy to adjust rent regulating causes doubts relatively to
2. it’s possible to linearize three phase EAF due to poor dynamic
servo valve dead zone regulating indications.
2.No possibility of definition of operating
speeds for different regulating error ranges
3.No possibility of servo valve gain proper-
ties linearization in significant shifting
ranges
The experimental investigations, carried out at OJSC
“MMK” steel-making shop on the base of EAF-180 have
shown that this technology will lead to increasing of EAF-180
average productivity to 5% on the account of power-on
operation time decreasing to 8%, and to low specific power
consumption to 1% [10].
VI. CONCLUSIONS
1) The main disadvantages of the most widespread electric
mode control systems of EAF is the adjustment difficulties
due to the closeness of its operating algorithms, no
linearization possibility of servo valve characteristic to
compensate its dead zone and gain properties in large shifts
range. It’s important to note that such important EAF energy
efficient indicators as power-on time and specific power
consumption depend directly on correct system setting.
 2016 2nd International Conference on Industrial Engineering, Applications and Manufacturing (ICIEAM)
Fig. 7. Simplified operational scheme of EAF electric mode control system “RADUGA NPA LF”.
2) In all modern electric mode control systems the main
criteria of transition from one heating stage to another is
specific power consumption. This parameter is connected
indirectly to real processes inside the furnace. The system of
heating stage diagnostic based on analysis of electric arc
current and voltage signals harmonic composition may
increase the productivity of EAF. The effectiveness of this
system is proved experimentally.
3) Adaptive proportional impedance regulator used in
“RADUGA NPA LF” system will help to gain the optimal
operating speed in the whole range of electric arc length
without non-linear gain block (HIREG system) or non-linear
proportional part (ARCOS). The system is rather flexible in
adjusting as the blocks of electric and hydraulic circuit
linearization have no any limits in the correction. The methods
of adjusting this system are open as the mathematical model of
EAF electric circuit defining linearising equations for electric
circuit is described in details in special literature.
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