The development of simulation and optimisation tools with an intuitive user interface to improve the operation of electric arc furnaces

Tomažič, Simon (author), Škrjanc, Igor (author), Andonovski, Goran (author), Logar, Vito (author)

The paper presents a novel decision support system designed to improve the efficiency and effectiveness of decision-making for electric arc furnace (EAF) operators. The system integrates two primary tools: the EAF Simulator, which is based on advanced mechanistic models, and the EAF Optimiser, which uses data-driven models trained on historical data. These tools enable the simulation and optimisation of furnace settings in real time and provide operators with important insights. A key objective was to develop a user-friendly interface with the Siemens Insights Hub Cloud Service and Node-RED that enables interactive management and support. The interface allows operators to analyse and compare past and simulated batches by adjusting the input data and parameters, resulting in improved optimisation and reduced costs. In addition, the system focuses on the collection and pre-processing of input data for the simulator and optimiser and uses Message Queuing Telemetry Transport (MQTT)communication between the user interfaces and models to ensure seamless data exchange. The EAF Simulator uses a comprehensive mathematical model to simulate the complex dynamics of heat and mass transfer, while the EAF Optimiser uses a fuzzy logic-based approach to predict optimal energy consumption. The integration with Siemens Edge Streaming Analytics ensures robust data collection and real-time responsiveness. The dual-interface design improves user accessibility and operational flexibility. This system has significant potential to reduce energy consumption by up to 10% and melting times by up to 15%, improving the efficiency and sustainability of the entire process.

• Language: English
• Keywords: electric arc furnace, energy consumption, process optimisation, decision support system, user interface, cloud services, Node-RED
• Work type: Article
• Typology: 1.01 - Original Scientific Article
• Organization: FE - Faculty of Electrical Engineering
• Publication status: Published
• Publication version: Version of Record
• Year: 2024
• Number of pages: 17 str.
• Numbering: Vol. 12, iss. 8, art. 508
• PID: 20.500.12556/RUL-159887
• UDC: 621.365.2:681.5
• ISSN on article: 2075-1702
• DOI: 10.3390/machines12080508
• COBISS.SI-ID: 203067395
• Publication date in RUL: 29.07.2024

Record is a part of a journal

• Title: Machines
• Shortened title: Machines
• Publisher: MDPI
• ISSN: 2075-1702
• COBISS.SI-ID: 17129750

Licences

• License: CC BY 4.0, Creative Commons Attribution 4.0 International
• Link: http://creativecommons.org/licenses/by/4.0/
• Description: This is the standard Creative Commons license that gives others maximum freedom to do what they want with the work as long as they credit the author.

Secondary language

• Language: Slovenian
• Keywords: elektroobločna peč, poraba energije, optimizacija procesa, sistem za podporo odločanju, uporabniški vmesnik, storitve v oblaku, Node-RED

Projects

• Funder: EC - European Commission
• Project number: 869815
• Name: Optimization and performance improving in metal industry by digital technologies
• Acronym: INEVITABLE

• Funder: ARIS - Slovenian Research and Innovation Agency
• Project number: P2-0219
• Name: Modeliranje, simulacija in vodenje procesov