Smart-Gas – A New Approach to Optimizing EAF Operations

Electric arc furnace (EAF) steelmaking presents complex operational challenges requiring real-time process monitoring and dynamic optimization to achieve consistent productivity, energy efficiency, and product quality. Jeremy Jones of Nupro, Sam Matson, and Paykan Safe of WorleyParsons Gas Cleaning Technologies collaborated to develop Smart-Gas, an innovative process optimization tool designed specifically for EAF operations. Traditional EAF control approaches often rely on operator experience and periodic measurements, leaving significant opportunities for improvement through continuous monitoring and data-driven decision support.

The Smart-Gas system integrates advanced sensors, process modeling, and analytical algorithms to deliver actionable intelligence for EAF operators and metallurgical staff. By continuously monitoring off-gas composition, temperature profiles, energy consumption patterns, and other key performance indicators, the system identifies optimization opportunities that might otherwise remain undetected. The real-time nature of Smart-Gas enables rapid response to process deviations, minimizing the duration and severity of off-specification conditions that can impact productivity, energy efficiency, and final product chemistry.

Implementation of the Smart-Gas optimization tool enables EAF operators to achieve measurable improvements across multiple performance dimensions, including reduced electrical energy consumption per ton of steel, shortened tap-to-tap times, improved yield through reduced metallic losses, and enhanced consistency in final product chemistry. The system's ability to provide continuous feedback on process conditions supports operator skill development and facilitates the standardization of best practices across production shifts and operating crews.

WorleyParsons Gas Cleaning Technologies' involvement in Smart-Gas development reflects the firm's commitment to delivering innovative solutions that address real-world operational challenges in metals production. The collaboration with Nupro demonstrates GCT's ability to integrate gas cleaning and emissions control expertise with advanced process control technologies, creating comprehensive solutions that optimize both production performance and environmental compliance.