A Review of Simulation and Numerical Modeling of Electric Arc Furnace (EAF) and its Processes

Electric Arc Furnaces (EAFs) play a pivotal part in the steel industry, offering a versatile of producing high-quality steel. This paper conducts an in-depth examination of the EAF, along with exploring mathematical modeling and optimization techniques pertinent to this furnace. Additionally, it delves into the global steel production capacity employing this technology, introduces different processes associated with EAF, scrutinizes the energy balance of EAFs, and provides an overview of numerical and simulation modeling in this context. The core focus of this extensive review is the diverse landscape of EAF simulation methods. It places particular emphasis on understanding the key components and stages of the EAF process, including charging, melting, refining, tapping, and slag removal. The review delves into the wide array of approaches and methodologies employed in EAF modeling, spanning from innovative computational fluid dynamics (CFD) and finite element analysis to the intricacies of mathematical and thermodynamic models. Furthermore, the paper underscores the importance of simulation in predicting and enhancing crucial aspects such as heat transfer, chemical reactions, and fluid dynamics within the EAF. By doing so, it contributes to the optimization of energy efficacy and the ultimate quality of steel produced in these furnaces. In conclusion, this review identifies gaps in existing knowledge and offers valuable recommendations for improving mathematical process models, underscoring the continuous efforts to enhance the efficiency, sustainability, and environmental impact of steel production processes. In conclusion, several techniques aimed at enhancing both production rates and the quality of the melting process in EAF have been put forward.