The development of online analysis methods for industrial electric arc furnaces (EAFs) has been a major research topic in recent years. Process control becomes even more important in the future due to the increase in both the usage of recycled metal as charge material and the metal recycling rate. For the industry to keep up with the pace, reliable chemical analysis of the slag together with online information about the furnace operation status is essential. Herein, optical emission spectroscopy is used to obtain the information about the electric arc together with radiative properties and surface temperature of the molten bath in an industrial EAF. The arc is visible for high alloyed steel grades within 5–30 min before tapping and the arc spectra are dominated by the optical emissions from the slag components. The plasma properties of the electric arc are determined with emission lines from atomic chromium, iron, and calcium. The time evolution of the spectra for high alloyed and carbon steel grades are compared with each other to provide a better understanding of the differences in the spectra between these two steel grades.

The heat transfer processes and the molten metal bath kinetics of the electric arc furnace are governed by the changes in the arc length and voltage. Thus, information on the electric arc behavior with respect to the voltage is important for accurate computation of the furnace processes and adjustment of the industrial furnace parameters. In this work, the length-voltage characteristics of electric arcs have been studied in a pilot-scale AC electric arc furnace with image analysis, electrical data from the furnace, and slag composition. The arc length was determined with image analysis and the relation between the arc length and voltage from test data. The relation between arc length and voltage was found to be non-linear and dependent on the slag composition. The voltage gradients of the arcs were evaluated as a function of arc length and sum of anode and cathode voltage drops resulting in a reciprocal relation. Furthermore, the electrical conductivity of the arc plasma with respect to arc length was estimated.

Due to the ever‐increasing demand for high‐quality steel and the need to reduce CO₂ emissions, research and development of sustainable steelmaking processes have gained a lot of interest in the past decade. One of these processes is the hydrogen plasma smelting reduction (HPSR), which has proven to be a promising solution for iron ore reduction where water vapor is formed instead of CO₂. However, due to the highly dynamic and sometimes unpredictable behavior of plasmas and their nonlinear interaction with the liquid oxides, the monitoring and control of the underlying processes must be improved. This article explores the usage of optical emission spectroscopy (OES) and image analysis for HPSR process monitoring at laboratory and pilot scale. The results cover the time evolution of the OES and camera data with the focus on the most interesting radiating species, such as atomic hydrogen, iron, and oxygen together with the FeO molecule. In addition, the advantages, disadvantages, and requirements of these methods for HPSR process monitoring are discussed.

Fundamental knowledge of the electric arc properties is important for the development of process control of electric arc furnaces. In this work, a pilot-scale AC electric arc has been studied with optical emission spectroscopy together with filtered camera footage. The properties of the arcs were determined with plasma diagnostics and image analysis in order to obtain both the characteristic plasma parameters and the physical form of the arc. The plasma temperatures, ranging from 4500 to 9000 K, were derived individually for three elements. The electron densities of the plasma were between 10¹⁸ and 10²⁰ cm⁻³ and fulfilled the local thermal equilibrium criterion, but the plasma temperatures derived from atomic emission lines for different elements had high and unpredictable differences. The properties of the electric arcs have been studied with respect to the arc length derived from the image analysis. The slag composition, especially the relative FeO content of over 30%, was observed to have a notable effect on the brightness of the arc on slag and thus also on the radiative heat transfer.

With the strict standards for steel quality and high production rates, the demand for faster and more convenient slag composition analysis for both electric arc and ladle furnaces has become a major issue in industrial steel plants. To overcome the time-delay between slag sampling and results of the slag composition analysis, an on-line slag composition analysis is required. Such a method that can be used in on-line analysis and is also chemically sensitive to the slag composition is optical emission spectroscopy. In this work, the optical emissions from the arc have been measured in an industrial ladle furnace and used for slag composition analysis. This article focuses on CaF2 and MgO, since the CaF2 is a common additive material in the ladle treatment and high MgO content means that the ladle refractory lining is dissolving into the slag. The analysis has been carried out by comparing emission line ratios to the XRF analyzed ratios of CaF2/MgO and MnO/MgO, respectively. The results show that several atomic emissions lines of calcium, magnesium, and manganese can be used to evaluate the CaF2/MgO and MnO/MgO ratios in the slag. It was found out that the plasma temperature derived from Ca I emission lines has a non-linear relation with the CaF2 content of the slag. Additionally, the dissociation pathways of molecular slag components were determined and studied in different plasma temperatures with equilibrium composition computation in order to determine the relations between the slag and plasma compositions.