Cost and Energy Effective Management of EAF with Flexible Charge Material Mix

Within the framework of the project FLEXCHARGE, performed within the RFCS steel research program, a team including research institutes and steel producers developed and tested in an industrial environment a methodology to effectively manage the EAF charged with variable materials. Statistical and deterministic methods were used together to determine yield and composition of different scrap types as well as the influence of the scrap mix on the off-gas emission and the slag composition. The paper summarizes the most relevant results obtained at four different EAF plants by applying the improved process control and by performing industrial trials for different steel grades. It also shows how the use of low quality scrap types in the charge mix has been maximized, considering the tramp element restrictions and scrap availability, yield as well as specific energy consumption.