Process Automation System ( Level II) of the EAF & LF

Level 2 automation systems of arc furnaces and ladle furnace, in addition to have capability of data collection from sites and storing, are presentable in an applicable form as well as controlling the production processes. By using the metallurgical model that predicts the melting and improves the melting process to enhance the quality of the final products. IRISA’s reliance on over 20 years of experience in the field of Level 2 system in large Steel factories of Iran and cooperation with renowned foreign companies in engineering, implementation, installation and maintenance of the systems, has started to Indigenize level 2 system for arc furnace and ladle furnace.

Role of Level 2 systems to improve the process of electric arc furnaces:

Level 2 system of electric arc furnace, with holding the control of materials charge and energy in the furnace and using predictive analysis models as well as melting temperature will optimization the induction furnace foam, reduces air pollution, conservative and improves energy usage to improve product quality which enormously helps the operators of this unit.

  1. A) role of Level 2 automation system in the increased production of slag foam:

Level 2 automation system using the following strategies will be effective in increasing the production of foam slag:

  1. uniformity of melting method by using static profiles and automatic mode
  2. The slag phase estimation based on the harmonics frequency of the current flow
  3. Calculate the slag flow instruments based on the harmonic situation
  4. Estimating the slag analysis

Slag foam benefits:

  1. Noise reduction of furnace
    2. Reduce erosion of furnace
    3. Protection of refractory center at the furnace roof
    4. Reduce of electrodes consumption
    5. Increasing the efficiency of DRI (due to reduced FeO slag)
    6.Promption of steel quality due to run off of melting impurities
  2. Increasing the efficiency of electrical energy
  3. Protection of body and roof of the cooling panel of furnace
  4. Reduce energy consumption of electrical energy by burning carbon
  5. The reduction of FeO slag
  6. Reduction of the amount of slag produced
  7. Reduction of the melting time

All these factors will increase the production and that is why the slag foam is known as alphabet in steel production.

  1. B) The role of level 2 system in the environment pollution reduction:

Level 2 system with reference to status of the different working conditions of the furnace in the smoke suction of level 1 automation system, causes the automatic control of the intake and exhaust smoke to be optimal, and effective operation of the furnace with optimum suction be removed from the site.

  1. C) the role of level 2 in the control of energy consumption oven:
  2. Set the exact amount of DRI charge by based on energy consumption
  3. Calculate the amount of power required to start next Cart or DRI charge
  4. Estimation of the melting temperature at any time and help to identify trends in energy consumption


  1. D) The role of level 2 system on the quality improvement of the melt:

Level 2 system by estimating the melting analysis at any time, will help to modify the melting analysis.

The role of Level 2 automation system to improve the process in the ladle furnace:

Level 2 automation system of ladle furnace with process control models and analysis estimation and melting temperature, have a major role helping in melting improving quality, reducing material consumption, improving operator efficiency and ease of data analysis of melt.

  1. A) Role of Level 2 automation system in improving the quality of melting:
  2. A method for estimating of melting analysis at all moments to help the correction of melt analysis.
    2. Assisting the operator in setting the analysis and proposal of suggestion to add needed materials into a ladle.
  3. B) Role of Level 2 automation system in reducing Consumable substances:
  4. Reduction of sampling due to continuous calculation of melting analysis
    2. Lance temperature consumption reduction followed by continuous calculation of temperature
    3. Reduction of additives use due to implementation of automated business processes tailored to metallurgical code
    4. Reduction of wire consumption required due to accurate calculation of the charge
  5. C) Role of automation system Level 2 in improving the efficiency of the operator:
  6. Provide guidance to the operator to carry out the production process according to pre-defined process and according to the metallurgical smelting.
  7. The production of appropriate warnings and messages (eg, alarms sound) based on the conditions encountered in the process of melting
  8. Showing of all activities and values as numbers and diagrams for better process control by operator
  9. Helping operator to adjust the analysis of the proposals to add into ladle
  10. Showing melt schedule and facilitate the defined operations
  11. D) The role of automation system Level 2 in surface melt at ease Data:
  12. Create a report of all used materials and the events during
  13. Statistical inference of values and display them for a change in strategy and process improvement

3.Rerun of process to observe the trend of values changes as well as through the process

Components of Level 2 automation system for electric arc furnace and ladle furnace:

 User Interface :

Manage User Interface Profile pages in a standard structure

  • Show all model output results
  • Show all levels of technology and standards
  • Manage custom views for each user individually
  • Operator input
  • Permission of changing the values of technological parameters for upper level operators


Showing all events of production sector and intake unit from the automation system level 1

Reports :

Providing daily and monthly reports and requested periods in different formats (Excel, PDF, …)

Control Process :

  • Follow the melting process and display Expenditures and events of each phase separately
    • Provide guidance and required warnings to optimize the process
    • Call for metallurgical models and provide the necessary data for them
    • Data storage in short intervals to allow further investigation and Tuning of models
    • Capability to implement automated processes with different profiles defined in the static format
    • Capability of performing the Automatic process in Dynamic mode

Metallurgical Models :

  • Calculation and estimation of the melting temperature
  • Predicting of the final melting temperature
  • Estimate the elements of melt
  • The estimation of the slag composition (in electric arc furnace)
  • Propose of ingredients to be added to the melt after receiving the real analysis of melt

External Interfaces :

  • Send and receive management of the values of automation system level 1
  • Send and receive Management of the values of automation system level 3

Process Simulation:

  • Complete simulation of automation system level 1 (production of sending signals to Level 2 and receipt of telegram from Level 2)
  • Complete simulation of automation system level 3 (production of sending signals to Level 3 and receipt of telegram from Level 3)