In this work, a practical approach for a decision support system for the electric arc furnace (EAF) is presented, with real-time heat state monitoring and control set-point optimization, which has been developed within the EU-funded project REVaMP and applied at the EAF of Sidenor in Basauri, Spain. The system consists of a dynamic process model based on energy and mass balances, including thermodynamic calculations for the most important metallurgical reactions, with particular focus on the modelling of the dephosphorisation reaction, as this is a critical parameter for production of high-quality steel grades along the EAF process route. A statistical scrap characterization tool is used to estimate the scrap properties, which are critical for reliable process performance and accurate online process control. The underlying process models and control functions were validated on the basis of historical production and measurement data of a large number of heats produced at the Sidenor plant. The online implementation of the model facilitates the accurate monitoring of the process behaviour and can be applied for exact process end-point control regarding melt temperature as well as oxygen, carbon and phosphorus content. Embedded within a model predictive control concept, the model can provide useful advice to the operator to adjust the relevant set-points for energy and resource-efficient process control.

The use of secondary raw materials in metallurgical processes such as steelmaking is an important contribution to the circular economy aspired to by EU members and many other countries. The agglomeration of dusts, fines and sludges is an important pretreatment step to enable the use of these materials in subsequent melting processes, such as steelmaking in electric arc furnaces (EAFs). It also reduces the amount of by-products and waste materials that are currently waste for disposal and are landfilled. The presented research is part of the Fines2EAF project, which aims to increase the value of steelmaking residues by internal recycling and use or reuse in the form of agglomerates. The approach followed in this project is the use of a hydraulic stamp press and alternative binder systems to produce cement-free agglomerates. The first results of lab-scale agglomeration tests of six different recipes with varying pressing forces are presented in this paper. It is shown that the addition of fibres from paper recycling has a strong effect on the cold compression stability of the agglomerates, by far exceeding other effects such as increased pressing force. Overall, the agglomerates produced in the lab show promising characteristics, for example, cold compression stability and abrasion resistance, which should allow for use in EAF steelmaking.

This paper approaches the energy transition towards decarbonization and lower primary energy use in the steel and glass industries through the exploitation of radiant waste heat. In contrast with exhaust gases heat recovery, radiant waste heat has typically not been used. This energy waste is found in energy intensive processes in which high temperatures are reached. For instance, in the steel making process, the cast steel is red hot and emits a considerable amount of radiant energy. In this paper the conceptual design of a radiant heat capturing device is presented. This device enables the recovery of currently unused energy while solving the radiative emission-related problems. The achieved design gets to an optimized solution regarding view factors and optical properties of the involved surfaces. In this research work, those factors are optimized to maximize the amount of heat recovered by the presented device. Simulation tools are used to test different designs and define the most appropriate solution for a given case.

Every day, a huge amount of energy is released into the atmosphere in the form of waste heat. The search for a cleaner and more efficient society, not only at the industrial level but also at the domestic level, should avoid this type of emissions. Steelmaking is an example of an industrial sector with high optimization potential in energy management. In this line, this work presents the main outcomes of the investigation carried out in the search of a technical solution for heat capture and reutilization from one of the main waste heat streams in the steelworks, the molten slag. For this purpose, a piping system embedded in the slag pit soil is proposed as a satisfactory solution for the heat capture operation. Besides, the internal applicability of this recovered heat is also addressed. Overall, the analysis carried out allows the identification of the maximum energy that can be recovered from the slag if the proposed technology is implemented (around 306 kWh_t per casting, which represents 6.3% of the total available energy). The work is completed with a preliminary techno-economic analysis which has shown a depreciated payback period of the proposed technology below 7 years.