الفهرس 
Introduction
EAF Process RemarksOnly 14 pages are availabe for public view
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Abstract
ABSTRACT The worldwide consumption of steel has been increasing over the past couple of decades at quite a high rate. It is expected to reach 763 million tons in the year 2005. Moreover, electric arc furnaces are considered to be the most efficient process that produces steel, both qualitatively and quantitavely. Electric energy is the primary power source in electric arc furnace. For that reason, this research will study the methods by which the Electric Arc Furnace steel production can be optimized in order to minimize its electric energy consumption. There are many factors that can affect the consumption of electric energy in Electric Arc Furnaces. The focus of this research will be the injection of carbon and oxygen, and the use of natural gas using the DANARC Module. 25 heat profiles were developed and tested on the furnace for 879 heats; these were filtered down and the six profiles, represented by 166 heats, with the most significant changes in parameters were selected for further investigation. A thorough comparison of the results yielded by these six profiles was made, and in the end, the most suitable profile was selected. The results indicate that the rate and sequence of carbon and oxygen injection into the furnace and the use of the natural gas burner can influence the savings of electric energy and productivity to a great extent. The results showed that: 1- It was found that the best O2 flow rate during the injection ranges from 94 – 100 Nm3/min. This flow rate starts directly after finishing the burner mode and continues as such till the end of the melting and refining process. 2- It was found that profile 13 has the lowest electric energy consumption of 386 kWh/ton. It is clear that this value is lower than the theoretical amount of heat required, which is 440 kWh/ton. This reduction in electric power is achieved by using oxygen injection, and thus, the energy cost per ton for profile 13 is the least of all, and is 80.48 EGP/ton of liquid steel. 3- It was found according to our calculations that the use of O2 is economical. 4- It was found that profile 13 has a lowest power on time, which is 36.15 min. 5- The injection of O2 inside furnace is important to initiate foamy slag to save electric energy, to decrease power on time, and increase productivity. 6- It was found that the use of fuel gas burner has limits as follow: ? The best burner flow rate with modules is 84 Nm3/min for O2 and 30 Nm3/min for CH4. The burners has to start from 0.70 min to 5.44 min in the 1st bucket. ? The best burner flow rate with modules is 84 Nm3/min for O2 and 30 Nm3/min for CH4. The burners has to start from 0.70 min to 3.67 min in the 2nd bucket. ? The best burner flow rate with modules is 84 Nm3/min for O2 and 30 Nm3/min for CH4. The burners has to start from 0.7 min to 2.98 in the 3rd bucket. This investigation is comprised of five chapters. The first introduces the global and local steel productions. Literature reviews of energy conservation methods are the topic of discussion of the following chapter. Chapter three explains the specifications and method of operation of the electric arc furnace used in the study. It also gave highlight to the module’s theory of operation and how it could be adjusted to achieve the desired results. In the same chapter, the different experiments that were done were also detailed. The next chapter then explains all the results that have been obtained from the performed experiments. The final chapter interprets these results.