Plume Analysis and CFD Modeling for EAF Meltshop Control

Electric arc furnace (EAF) operations generate substantial volumes of particulate-laden emissions that, if not effectively captured, contribute to workplace air quality problems, visible stack emissions, and environmental compliance challenges. The complex, transient nature of EAF emissions—including variations in plume characteristics during different melting stages—makes optimization of capture hood systems particularly challenging. Gas Cleaning Technologies developed an integrated analytical approach combining computational fluid dynamics modeling with video-based plume analysis techniques to systematically evaluate and improve EAF emissions capture efficiency.

The methodology employed by GCT utilizes CFD simulation to model airflow patterns, velocity fields, and contaminant dispersion characteristics within the meltshop environment under various operating scenarios. Complementing the computational analysis, video plume analysis provides visual documentation of actual emission plume behavior, trajectory, and the effectiveness of existing capture systems during normal production conditions. This combined approach enables identification of specific operational phases or conditions where fugitive emissions occur and quantifies the performance gap between current and optimized system configurations.

Analysis results provide actionable engineering recommendations for improving capture hood design, adjusting exhaust flow rates, optimizing hood positioning, and implementing operational practices that minimize fugitive emissions. The techniques demonstrated in this publication enable facilities to achieve measurable improvements in capture efficiency without necessarily requiring major capital equipment replacement, often through strategic modifications informed by data-driven analysis.

For steel producers and EAF operators facing environmental compliance pressures, community relations concerns regarding visible emissions, or workplace air quality challenges, this publication demonstrates proven diagnostic and optimization methodologies. Gas Cleaning Technologies' expertise in applying advanced modeling tools and field analysis techniques addresses the practical realities of EAF emissions control, delivering solutions that balance environmental performance, operational flexibility, and economic constraints.