Electric Arc Furnace (EAF) Off-Gas Extraction and Waste Heat Recovery Optimization
Problem Definition
Industry Challenges
- 01 Stringent environmental regulations regarding particulate matter (PM) and NOx emissions in steelmaking
- 02 High energy intensity of EAF operations with significant thermal losses through off-gas systems
- 03 Fluctuating process conditions (charging, melting, refining, tapping) requiring dynamic system response
Specific Pain Points
- Fugitive emissions escaping the canopy hood during charging and tapping cycles
- Accelerated wear and leakage in water-cooled ductwork due to thermal cycling and abrasive dust
- Inefficient fixed-speed operation of Main ID Fans leading to excessive power consumption during non-peak phases
- Risk of CO explosions in the secondary combustion chamber due to improper draft control
Current State Analysis
Performance Impact
Engineering Verification
This solution has been validated by Atlamech Engineering based on the following standards:
View DetailsTechnical Scope
- Computational Fluid Dynamics (CFD) modeling of the canopy hood and 4th hole extraction geometry
- Integration of Medium Voltage VFDs for Main ID Fans (2x 2.5MW) with closed-loop draft control
- Retrofit of evaporative cooling tower with a Waste Heat Recovery (WHR) boiler system
- Implementation of SIL2-rated CO monitoring and explosion venting systems
Compliance Standards
Implementation Strategy
Key Deliverables
Consultation Notes
Process Safety & Integrity
The primary safety concern in EAF off-gas systems is the accumulation of Carbon Monoxide (CO). The control system must include independent, hardware-based interlocks (SIL2) to open emergency dilution dampers if CO levels exceed 1.5% prior to the baghouse. VFDs alone are not sufficient for safety-critical draft control during emergency venting.
Thermal Management
To prevent acid dew point corrosion (H2SO4 formation), the gas temperature at the baghouse inlet must be maintained above 110°C, while strictly kept below 140°C to protect filter media. This requires a cascade control loop modulating the water injection rate in the quenching tower based on exit temperature.
Duct Design
Ductwork routing should minimize 90-degree bends to reduce pressure drop and abrasive wear. Where bends are unavoidable, use hardened wear plates (e.g., Chromium Carbide Overlay). Minimum transport velocity of 18 m/s must be maintained even during low-load VFD operation to prevent dust dropout.
Infrastructure Taxonomy
Knowledge Areas
Implementation Evidence Summary
Project Brief
Electric Arc Furnace Off-Gas Extraction and Waste Heat Recovery Retrofit
Technical Knowledge Cluster
EAF Off-Gas Management and Energy Recovery Systems
A technical cluster addressing the engineering principles of Electric Arc Furnace fume extraction, thermal energy recovery strategies, and emission control compliance for steel manufacturing facilities.
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