ArcSave ® , Innovative Solution for Higher Productivity and Lower Cost in the EAF

ArcSave ® is a new generation of electromagnetic stirrer (EMS) from ABB for electric arc furnace (EAF) operation which aims to improve the safety, increase the productivity and reduce the cost. Electromagnetic stirring of the melt bath during arc furnace operation will affect the arc stability, scrap smelting, bath temperature distribution, refining reactions, and also the tapping practice. This paper has summarized the investigation results obtained from the first ArcSave ® system installed in a 90ton EBT arc furnace at Steel Dynamics, Inc. (SDI), Roanoke, VA USA. The hot test results show that ArcSave ® has stabilized the arc and enhanced the heat and mass transfer in the arc furnace process which result in a faster scrap melting rate, lower the slag superheat during arcing, more homogenous melt bath, and higher decarburization rate, and higher EBT opening frequency. ArcSave ® has also reduced the tapping temperature and tapping oxygen in the steel which brings a higher scrap yield and saves ferroalloy consumption in the downstream ladle furnace operation. The lower energy consumption, short tap-to-tap time, and consistent furnace operation greatly increases the productivity and operation safety.