The i EAF^® (Intelligent Electric Arc Furnace) is a comprehensive process control system for the EAF. Based on real-time measuring of EAF off-gas composition and temperature, mass & energy balances and in conjunction with real-time process inputs, dynamic information is revealed to determine; mass-rate of off-gas leaving the EAF; rate of air inleakage; rate of decarburization; rate of oxidation; rate of water entering the freeboard of the EAF and the contribution of chemical energy to the heating and melting of steel.

i EAF^® controlled furnaces are paced according to the total energy (electrical plus chemical) supplied to the scrap. Combustion optimization is achieved by closed-loop control of burner oxygen and methane based on calculated (not estimated) heat transfer efficiencies and economics. Control of carbon and oxygen injection, via dynamic state-space modeling of the slag and bath composition, make it possible to maintain optimal slag properties for effective slag foaming over the whole of the refining period.

With response times typically below 20 seconds from sample point to analysis, this new generation of EFSOP^® analyzers PLC controls are easily integrated into the steel-maker's level 1 system. In addition to measuring off-gas composition, the i EAF^® system provides a dynamic measure of off-gas temperature at the fourth hole.