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EAF Energy Optimization at Nucor Yamato
Omar QuintanillaRegulation EngineerNucor-Yamato Steel Company5929 Highway 18 EastArmorel Arkansas 72310870-762 5500 ext 146oquintanilla@nucor-yamato.comGuillermo FernandezTechnology ManagerAMIGE InternationalBlvd Gustavo Diaz Ordaz 402 Piso 2Monterrey NL, México 64650(52) (81) 1001-4076gfernandez@amige.com
Introduction
 
Nucor Yamato Steel is continuously working to improve the operations all time. The energy input optimization has always beenat a good performance level, but there is always been turnarounds on the way to achieve better results. The most difficult partof the adjustment process is that the control system is divided into several control sub-systems which interact between eachother. These sub-systems do not take into account the effects of changes made to another sub-systems, and are developed bydifferent vendors in their own knowledge area. As an example, reducing the exhaust gas negative pressure may produce lessenergy losses, but it may cause the furnace to be more prone to cross-arcing and so to damages and loss of time. In order tooptimize the EAF process as a whole, new SmartFurnace modules were added to the SmartArc system. The SmartArc controlsystem has been in place since 1997 for controlling the electrical energy input at NYS. The new SmartFurnace modules wereadded in order to take on-line control of the Burner System and the Exhaust Gas system. In this paper we will first present adescription of the EAF system, then we’ll talk about the main issues in the pursue of high performance, then we will present abrief description of the new control modules and their added flexibility in order to cope with the main variations in the other sub-systems. Finally we’ll show some of the new features tested and the evolution of some of the adjustments and the results.
 
System description
Electrical System
NYS has an AC EAF with a 90MVA transformer with a two position online reactor. Using a 0.609 meter electrode diameter in a ina 1.12 meter pitch circle diameter.Figure 3. The Table has the transformer low voltage amps and volts in all the tap positions.
Xfrmr tap 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33Sec volts
929 940 947 958 966 978 986 994 1,002 1,015 1,023 1,036 1,045 1,055 1,064 1,078 1,088 1,098
HV currentA
1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506 1,506
LV cuerrentkA
55.94 55.30 54.87 54.22 53.79 53.14 52.71 52.28 51.85 51.21 50.78 50.13 49.70 49.27 48.84 48.20 47.77 47.34
MVA
90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0 90.0
Burner System
Four burners are located around the shell generating 6.9 MWeach.The three port burners are used in Burner Mode creatingcombustion between low flow oxygen and natural gas, the LanceMode uses supersonic oxygen flow and injected carbon.The nominal flows are:10.5 m3/min Natural Gas42 m3/min Oxygen Gas40 kilogram/min CarbonFigure 4. The fourburners modules in thefurnace
Shell
The shell was designed to tap 122 metric tons and handle 10% of hot heal.
Exhaust Gas System
The exhaust gas system control keeps a constant pressure inside the furnace during regulation. This is possible by a pressuretransmitter inside the furnace shell and a variable damper position. A step table is used to change the pressure set-point duringthe heat.
System Control
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