Multi-physics modeling and optimization of DC electric arc furnace based on operating parameter and field synergy analysis

The global steel industry is under growing pressure to boost energy efficiency and reduce environmental impacts, highlighting the worldwide significance of optimizing industrial heating processes. For Direct Current Electric Arc Furnaces (DC EAF), optimizing multi-physical fields is essential to increase productivity and lower energy use. This study examines DC EAFs using a multi-physical field synergy approach, offering insights to improve control of arc parameters and electrode configurations. Using a magnetohydrodynamic (MHD) model for numerical simulation, the research follows international trends in advanced metallurgical studies. The MHD model simulates the electromagnetic, velocity, and temperature fields within the furnace. It then evaluates how anode structure, arc length, and current affect these fields. By applying the field synergy principle, interactions among these fields are optimized to boost heat transfer efficiency. Results show that modifying arc parameters (arc length and current) and anode structure significantly improves the synergy between velocity and temperature fields, enhancing heat transfer. Three distinct molten steel flow patterns emerge under different conditions, influenced by changes in the Lorentz force at the bath base. Optimal performance is achieved with an arc length of 45 cm, arc current of 60 kA, and the CLECIM anode structure. Compared to the least optimal scenario, temperature–velocity field synergy improves by 6.6 %, and temperature rise increases by 2.2 %. These outcomes support global sustainable steel production by offering a scalable, energy-efficient operational framework, holding substantial value for both research and industry.