Optimization of Scrap Melting Using an Electric Arc in Steel Manufacturing

Steel industry is crucial to the national economy and security. Around 67% of crude steel in the U.S is produced in electric arc furnaces (EAF), which is energy intensive. Around 140 EAFs operate in the U.S., consuming about 8.6x107 MMBtu/year of electricity. One of major challenges for EAFs includes maximizing the efficiency of the electrical energy provided in the form of electric arcs to melt various scrap mixes. To address this issue, a computational fluid dynamics (CFD) methodology is chosen to analyze scrap melting using the electric arc. Due to complex furnace phenomena and the wide variety of potential scenarios, high performance computing (HPC) is essential to yield comprehensive and detailed CFD analyses and systematic parametric studies for optimized EAF operation. The objectives are to 1) simulate scrap melting using electric arc, 2) evaluate electrode/arc position for optimum scrap melting and 3) establish reduced order model for CFD data-base for fast model calculation.