Electric furnace equipment intelligent automation (DCS) system

Overview of equipment functions and uses:

  This equipment is mainly used to control the automatic operation of the electric furnace, electrical automation equipment such as PLC (programmable logic controller) and industrial computer for real-time monitoring and automatic control of the production process, improve production efficiency and product quality. ‌

Main performance level parameters:

  The main low-voltage components are Schneider, ABB and other well-known brands, the PLC is Siemens 1500 series, and the upper computer is Wincc7.5.

Equipment component composition:

  It is mainly composed of low voltage control cabinet, PLC control cabinet, main operating station, computer station, field control box terminal box, etc.

Intelligent Automation (DCS) System for Electric Furnace Equipment

Overview

Core Functions & Features

1. Real-Time Monitoring & Data Acquisition

• Multi-Parameter Sensing: Tracks critical process variables, including:
  • Temperature: Molten pool temperature (via thermocouples or infrared sensors), furnace wall temperature, flue gas temperature.
  • Electrical Parameters: Input current, voltage, power consumption, and electrode position (for arc stability).
  • Material Status: Raw material feeding rate, molten material level, viscosity, and tapping flow.
  • Environmental Data: Flue gas composition (SO₂, NOₓ, dust), pressure, and emissions.
• Centralized Visualization: A user-friendly HMI (Human-Machine Interface) displays real-time data trends, equipment status, and alarms through intuitive dashboards, allowing operators to monitor the entire process at a glance.

2. Automated Process Control

• Temperature Regulation:
  • Uses PID (Proportional-Integral-Derivative) or advanced model-based control algorithms to maintain molten pool temperature within a precise range (e.g., 1500–1600℃ for rock wool production). Adjusts heating power (e.g., electrode current) or feeding rate automatically to compensate for fluctuations.
• Electrode Management:
  • Automatically controls electrode lifting/lowering to maintain optimal arc length, preventing short circuits or unstable arcs. Reduces electrode wear and energy waste.
• Material Handling Automation:
  • Synchronizes raw material feeding (via conveyors or screw feeders) with melting demand, ensuring a consistent supply of materials. Automates tapping operations based on molten material level and viscosity.
• Energy Optimization:
  • Monitors power consumption in real time and adjusts operation parameters to minimize energy usage (e.g., shifting to lower power during off-peak hours or optimizing electrode spacing for efficient arc heating).

3. Fault Diagnosis & Safety Interlocks

• Predictive Maintenance:
  • Analyzes historical data and real-time trends to detect potential equipment failures (e.g., refractory wear, electrode degradation, sensor malfunctions) before they occur. Sends early warnings to maintenance teams, reducing unplanned downtime.
• Safety Protocols:
  • Implements interlocks for critical safety scenarios, such as:
    • Emergency shutdowns if temperature/pressure exceeds safe limits.
    • Automatic electrode retraction in case of short circuits.
    • Isolation of gas/electric systems during maintenance.
  • Records safety events and alarms for compliance and audit purposes.

4. Data Logging & Reporting

• Comprehensive Data Storage: Logs process data, equipment status, and operator actions at configurable intervals (e.g., 1-second to 1-minute increments). Stores data locally or in the cloud for long-term analysis.
• Customizable Reports: Generates reports on key performance indicators (KPIs), including:
  • Energy consumption per ton of product.
  • Production efficiency and output.
  • Material usage and waste rates.
  • Equipment uptime and maintenance costs.
• Compliance Support: Helps meet regulatory requirements (e.g., ISO 9001, environmental emissions standards) by providing accurate, auditable records.

5. Remote Operation & Integration

• Remote Access: Enables operators to monitor and control the furnace from off-site locations via secure networks (e.g., VPN or cloud-based platforms). Facilitates remote troubleshooting and support.
• System Integration: Seamlessly connects with other plant systems, such as:
  • MES (Manufacturing Execution System): For production scheduling, inventory management, and order tracking.
  • ERP (Enterprise Resource Planning): For cost accounting, procurement, and supply chain management.
  • IoT Platforms: For advanced analytics, machine learning, and AI-driven process optimization.

Technical Specifications

Benefits

• Increased Efficiency: Reduces energy consumption by 5–15% and improves production throughput by optimizing process parameters.
• Enhanced Product Quality: Minimizes process variability, ensuring consistent product properties (e.g., fiber diameter, thermal conductivity).
• Reduced Downtime: Predictive maintenance and fault diagnosis reduce unplanned downtime by up to 30%.
• Improved Safety: Automated safety interlocks and remote operation minimize operator exposure to hazards.
• Cost Savings: Lower energy, maintenance, and labor costs, with faster ROI (typically 12–24 months).

Applications

• Mineral Wool Production: Rock wool, glass wool, and slag wool electric furnaces.
• Metal Smelting: Electric arc furnaces (EAF), induction furnaces for steel, aluminum, and copper.
• Advanced Materials: Ceramics, composites, and refractory melting processes.

Why Choose Us?

• Expertise: Over 15 years of experience in industrial automation and DCS integration for high-temperature processes.
• Customization: Tailor-made solutions to match your specific furnace type, production scale, and operational needs.
• Support: 24/7 technical support, on-site installation, training, and maintenance services.
• Innovation: Continuous R&D to integrate AI, machine learning, and IoT for next-generation smart furnace control.