Improving the Energy Efficiency of Electric Arc Furnaces and Analysis of High Harmonic Impacts

Abstract

Relevance: at present, the metallurgical industry is one of the largest consumers of electrical energy, and electric arc furnaces have a significant impact on power supply systems as high-power and nonlinear electrical loads. During the operation of electric arc furnaces, unstable arc burning causes distortion of current and voltage waveforms, leading to the generation of high-order harmonics in electrical networks. These harmonic effects result in deterioration of power quality, increased additional losses, and overheating of transformers, cable lines, and distribution equipment. The limited availability of energy resources, rising electricity tariffs, and stricter energy efficiency requirements imposed on industrial enterprises make the improvement of energy efficiency in electric arc furnaces increasingly important. Reducing electricity consumption not only lowers production costs but also decreases greenhouse gas emissions associated with power generation. At the same time, mitigation of high-order harmonics enhances the reliability of power supply systems and limits adverse impacts on power quality for other consumers. Therefore, research aimed at reducing harmonic effects and optimizing energy losses in electric arc furnaces is of great scientific and practical importance for sustainable industrial development.

Aim: the objective of this study is to experimentally identify effective technical and control methods for improving the energy efficiency of electric arc furnaces and reducing their harmonic impact on power supply systems.

Methods: the study was carried out based on experimental measurements, spectral analysis of the harmonic content of current and voltage, and comparative analysis of compensation and adaptive control operating modes.

Results: it was found that energy performance indicators and harmonic characteristics vary significantly at different operating stages of electric arc furnaces. The application of adaptive electrode control and reactive power compensation improved arc stability and reduced peak current values. As a result, the specific electrical energy consumption per ton of product decreased by 1%. In addition, a reduction in the overall current harmonic distortion was observed, leading to improved power quality. These results contribute