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Electrics & Automation for Steelplants

ISEC – SMART ELECTRODE CONTROL

ISEC – SMART ELECTRODE CONTROL – A STEP CLOSER TO YOUR SMART PROCESS

ISEC controls the electrode movement dynamically at an optimum working point to achieve maximum efficiency when converting the electrical energy into heat.

ISEC was developed while considering modern operation requirements in electric arc and ladle furnaces used within the iron and steel industries (EAF, LF, VHD/VAD). Additionally, ISEC can control submerged arc operation; this extends the range of application to all sorts of electric furnaces used for non-ferrous metals, ferroalloys and slag heating.

The new ISEC digital electrode control system is based on a state-of-the-art embedded controller which enables real-time sampling and accurate calculations of all electric values. The Smart Electrode Control also integrates a modern web-based visualization system that provides flexible operation and fast diagnostics. 

YOUR BENEFIT

  • Increased productivity
  • Maximum energy efficiency
  • Reduced electrode and refractory consumption
  • Fast return on investment
  • Individual customized reporting & analyze tool 
ISEC Features

IMPROVE YOUR FURNACE – OPTIMIZE YOUR PROCESS BASED ON ACTUAL & HISTORICAL DATA

All relevant furnace information at a glance

  • Working point
  • Voltages
  • Currents
  • Velocities
  • Arc lengths
  • Energy input

Special Features

  • Automatic dip test procedure with plausibility check of the measured data
  • Automatic valve scaling procedure
  • Adaptive set point and deadband control
  • Foaming slag control via fuzzy logic
  • Historical database for 24 hours with a sampling rate of 0,1 s and one year with a sampling rate of 1s
  • Historical database of statistical values for the whole furnace life time

Be informed - no matter where you are

  • The user interface works natively in any web browser with no need to install additional software or plugins. It can be operated through devices such as desktop PCs, industrial computers, tablets or smart phones.
  • All functions accessible via web-based HMI 

ISEC – SMART ELECTRODE CONTROL:

Not only a controller but also a database server that can be fully integrated into your smart factory – INDUSTRY 4.0 READY 

The proper working point for each furnace is essential to achieve an optimal electric power input.

ISEC offers several diagrams to help determine this point. 

  • Furnace circle diagram and arc length diagram with actual and historical working point data
  • Current phase symmetry

Individual customized analysis

  • Trend analysis
  • Key performance indicators (e.g., power consumption, power-on time, tap-to-tap time, etc.)
  • Analysis can be adapted via the dashboard designer 

Operating profiles

  • Up to 100 operating profiles
  • Intuitive operator handling
  • Monitoring of the actual process step

Individual customized reporting

  • Heat reports
  • Can be adapted via the report designer
ISEC FUNCTIONALITY OVERVIEW

System

  • Compact size
  • Standard state-of-the-art hardware components
  • Peltier cooling system for internal hardware components
  • Plug-and-play philosophy
  • Web browser-based HMI 

MEASURING

  • Signal processing and visualization of process relevant parameters, e.g., I, U, P, Q, S, Pf, X, Z, R, etc.
  • Calculation and analysis of harmonics and THD
  • Compensation of neutral point displacement
  • Data acquisition @ 2.5 kHz
  • Database recording 

Controller

  • Controller for EAF, LF, VHD and non-ferrous furnaces
  • Advanced impedance control
  • Fine control range
  • Dead zone range
  • Melt current setpoint
  • Adaptive setpoint control
  • Adaptive deadband control

Furnace Diagram

  • Automatic calculation of furnace diagram
  • Monitoring of actual working point
  • Circuit diagram (P, Q) or power diagram (P, I)
  • Single electrode or total average value

Automatic Control

  • Automatic dip test procedure with calculation of high current system parameter and plausibility check
  • Synchronized start procedure
  • Overcurrent protection
  • Nonconductive material detection
  • Automatic valve scaling procedure
  • Foaming slag control via fuzzy logic

Operating Profiles

  • Up to 100 operating profiles
  • Intuitive operator handling
  • Monitoring of the actual process step

Parameters

  • I,Z setpoint table
  • Transformer, reactor and grid data
  • Store and load different data sets

Service

  • Remote access service
  • Our team of electrical, automation and metallurgy engineers offers a special service that evaluates and optimizes your furnace’s operation and performance 
ISEC SYSTEM CONFIGURATION
ISEC SYSTEM DATA

Technical Data

Item Data
ISEC cabinet Stainless steel, 480 x 690 x 330mm (wxhxd) approx. 40kg
UI-box Stainless steel, 500 x 500 x 300mm (wxhxd) approx. 20kg
Power supply 230 VAC (1A)
Monitor Multi-touch, 17”
Main cylce time < 10 ms
Current measurement Rogowski coils or current transformer (primary or secondary)
Voltage measurement Protected voltage transformer
Control output -10V ... +10V standard, different configuration e.g. +/- 300mA or +/- 200 mA are available on request
Ambient temperature -10 ... +45°C
Relative humidity 5 ... 90%

Interfaces

Technology Protocol
Ethernet OPC Server, Profinet, EtherCAT, TCP/IP
Fieldbus-system Profibus DP, DeviceNet, Modbus, CANopen ...
IFOB Furnace Optimization Box

With rising energy costs and stricter environmental protection laws, steel plant operators are now forced to reduce costs and optimize equipment performance more than ever. As the biggest consumer of electric energy and raw materials, EAFs feature a high potential for cost and raw material savings, as well as serious risks when operated outside optimal ranges. A key factor in an environment of widely varying production parameters is the use of an automated online process optimization system.

INTECO's Furnace Optimization Box (IFOB) is an intelligent process control system which continuously collects all relevant furnace data (field sensors and instrumentation) for a permanent online model of real-time heat and furnace conditions, thus optimizing the overall energy balance in a holistic manner. The IFOB’s modular design offers different feature configurations and is easily adapted for and installed in existing furnaces.

The IFOB process optimization system is built around a central data management system, featuring all the specific optimizing parameters for each individual steel grade, plus a comprehensive data analysis system. The automated process ensures reproducible and optimized results in terms of heat target conditions and energy minimization. 

IFOB is a platform for establishing overall process control in Electrode Arc Furnaces (EAFs). 

  • Knowledge-based system with an integrated inference engine
  • Enables dynamic process control
  • Reduces costs & time
  • Extends the lifetime of your furnace
  • Improves your process & and steel quality
  • Report & and analysis tool 
IFOB FUNCTIONALITY OVERVIEW

Measuring

  • Direct, independent measurement of electrical values
  • Fast-sampling analog inputs for critical values
  • Export of all measured and calculated values to csv or xls 

CONTROL

  • Setpoint control and event generation via configurable fuzzy control engine
  • Graphical tool for if-then analysis and detailed overview of rule impact on fuzzy configuration 

OPERATING PROFILES

  • Individual profiles for grade groups and single grades
  • Different profile strategies available (fast, economic, cold furnace)
  • Multiple trigger variables for step forwarding 

FURNACE COCKPIT

  • All KPIs at one glance sight
  • Current furnace condition compared to historical data
  • Prediction of production events (next basket, temperature reached, etc.)
  • Complete charge reporting included 

OPEN ARCHITECTURE

  • Connect all pre-existing components with a standard fieldbus, web service interface or hardware signals
  • Plug & play philosophy for straightforward integration and high connectivity
  • Supports third-party systems and sensors 

SCALABLE

  • Capability  to operate without additional sensors
  • Functionality grows with new equipment and sensors
  • Model-driven soft sensors 

SYSTEM

  • Industrial-grade standard components
  • IFOB configuration-tool
  • 320 GB storage capacity for approx. 20 years of heat data 

SERVICE

  • 1 year service contract included
  • User data export leaves the customer in full control of sensitive production data