iSAM has recently implemented the complete level I and level II automation into an electric steelmaking shop. Here, the twin-shell electric arc furnace does not only serve for melting the charge, a mixture of scrap, DRI (direct reduced iron) and hot metal. Oxygen blowing can also be performed in the same vessel.

Level II was extended to the complete steel melting shop including ladle furnace, vacuum degassing and alloy optimisation, also integrating associated laboratories. The system architecture was completely redesigned for the EAF shells each of which is further equipped with all the PLC and HMI systems.

The implemented Level II system further comprises a data acquisition system and several process models. An integrated process model was customized to govern steelmaking operation, i.e. it allows the prediction of steel composition and temperature at different process sequences. Another model synchronises the two shells with the treatment steps melting and oxygen blowing, thus making best usage of the transformer.

An online cost calculation and optimisation module considering the wide range of raw materials and energy available determines the optimum charge mix.

Control and visualisation of the EAF is now based on five Siemens S7-400 PLCs and an Intouch HMI system with fully redundant servers and eight operator stations. Each shell of the EAF is equipped with own PLCs and HMI.

For the first time, all auxiliary systems are also included in the central HMI. This integration is of special advantage as it provides the operator with a homogeneous user interface of identical look-and-feel.

Pre-defined standard operating procedures provide the basis for a continuous production quality independent of the operator, who is automatically guided through all production steps. Anytime, he has access to all production figures, as documentation is performed automatically.

This customised automation solution is just one example how to increase an electric steelwork´s production and profitability.