EAF Ultimate – High Flexibility and Fully Automated Operation
German steel producer Dillinger and its subsidiary ROGESA have signed contracts for the supply of a new production complex, which includes an EAF Ultimate electric arc furnace plant including two twin ladle furnaces.
The EAF Ultimate represents Primetals Technologies’ latest development in electric steelmaking. The fully automated plant will ensure short tap-to-tap times and reduced consumption. It offers high flexibility in terms of raw material input and the production of a wide range of steel grades.
Primetals Technologies extensive scope of supply for the new meltshop includes a 195-ton furnace with a 9.6-meter furnace diameter and a powerful 300 megavolt-amperes (MVA) transformer, the LiquiRob robotics system for enhanced safety operations, two 195-ton twin ladle furnaces (LF), a material handling system, primary, secondary, and auxiliary dedusting systems for the EAF plant, a waste heat recovery system, and a water treatment plant. The heat recovery system converts waste heat into steam, which will be reused in other production units.
The EAF Ultimate will feature advanced Level 1 and Level 2 automation systems, including the EAF Controller and EAF Optimizer, enabling both closed-loop control of the furnace for a precise fulfilment of the desired product quality and detailed production planning.
Comprehensive Digitalization Solutions
A swift implementation of learnings and evaluations will play a key role as the new production complex is put into operation, which places high demands on the automation systems. Both plants will be equipped with the latest digitalization solutions from Primetals Technologies. The condition-monitoring system Asset Life Expert (ALEX) identify potential incidents before they occur to support predictive maintenance, which together with the Lomas off-gas analysis system will enhance process-efficiency and safety.
Primetals Technologies’ virtual plant solutions for both the DRI and the EAF plant will allow testing of software and operator training before startup and throughout the entire lifecycle of the plant, ensuring a smooth ramp-up of production. Moreover, the scrap yard will be equipped with AI-based sensor systems, allowing fully automated operation of the scrap yard.
The Melt Expert electrode control system will be installed at both the EAF plant and the LFs, offering productivity gains and cost-savings related to reduced consumption.
