DANIELI DIGIMELTER

Q-ONE TECHNOLOGY

Efficient energy source

for electric furnaces through
Hi-performance power unit
A TECHNOLOGICAL
BREAKTHROUGH
IN THE EAF
PROCESS AREA
Electric Arc Furnace represents one of the most > Hi-levels of active & reactive power absorbed
intensive disturbing loads in the electric power from the electrical supply network in an unbalanced
transmission systems, it is featured by rapid and untimely manner, causing huge disturbances
changes in absorbed power that occurs especially (harmonics and flicker) affecting the proper
in the initial phase of melting, during which the functioning and operation of other connected loads;
critical condition of an interrupted arc may become > Efficient use of energy through process
a short circuit or a open circuit. optimization with great room for improvements and
Actual furnaces design provides very large input savings;
ratings and due to nature of both, electrical arc > Suitability for existing EAF modernization projects,
and meltdown process, these equipment can with a flexible power and control configuration
generate large power quality problems on grid as to meet existing arc ratings and physical furnace
non symmetric current & voltage, harmonics, shape.
flickers, voltage imbalances and drops, over
voltages. The Q-ONE family of special power converters
minimizes network disturbances, handle large
Conceived as innovative solution to supply the load unbalances, and virtually absorb almost all
AC Electric Arc Furnaces, Q-ONE is a Danieli active power in a balanced manner from the supply
Automation’s designed and patented equipment network. A specifically designed patented control
that uses latest power electronics technology system and configuration makes it possible to
to handle irregular loads in a more flexible and reduce the transients that are known to wear out
reliable way, and values of power factor close to the EAF components during the melting cycles,
unity. Q-ONE extends the Power System products significantly reducing maintenance stops and
range to the high-power systems used for EAF the cost of wearable parts, and at the same time
steel melting, where well-known challenges have optimizing the melting process.
to be addressed:
Higher power Very low network High reliability
factor thanks flicker due to real of Q-ONE
to a limited time control on equipments
exchange of the arc current because its
reactive power variation modularity
with MV network and wide design
margins
DANIELI AUTOMATION

Impact onto the feeding network Q-ONE reliability

Differently to a static var compensation system, > Rated voltage of Q-ONE equipment chosen
the Q-ONE system acts onto the source of the with wide design margins;
conducted disturbances and not on their effect > Possibility to easily exclude three-phase modules
onto the network. The basic concept of Q-ONE is to in case of fault;
separate the furnace working environment from the > Possibility to easily exclude single units aboard
dedicated feeding network Q-ONE modules in case of fault;
> Remote control via WEB for maintenance
Q-ONE flexibility and data monitoring.
> Extremely high speed control of voltage and
current in the furnace Q-ONE layout
> Real time control of the supply voltage of EAF On request, the Q-ONE system installation can
> Real time control of the arc current thus of short be designed with the possibility to easily switch
circuit phenomena between the existing furnace feeding system
> Possibility to run the furnace with two phases and the new one.
only, with zero impact to network The existing furnace transformer can be
> Possibility to act onto the outpt frequency
FEEDING disconnected
FURNACEfrom the secondary and moved
(typical 30 to 70 Hz) NETWORK backwards, whilst the primary side can be isolated
ENVIRONMENT
ENVIRONMENT

NETWORK FURNACE
ENVIRONMENT ENVIRONMENT

THE BASIC CONCEPT IS TO SEPARATE

FURNACE ENVIRONMENT
FROM FEEDING NETWORK

W5 MOD.
2500 A (*)

W4 MOD.
2500 A (*)

W3 MOD.
2500 A (*)

W2 MOD.
2500 A (*)

W1 MOD.
2500 A (*)

4
 QONE POWER UNIT

1 The Q-ONE basic concept

(Pst)
(Pst)
(Pst) 2 Q-ONE equipment
333
WITHOUT
WITHOUT
WITHOUTQONE
QONE
QONE and modules design
2,5
2,5
2,5 (*) upgrade to 5KA
under study

+
222
1,5
1,5
1,5
3 Impact onto the feeding
WITH
WITHQONE
QONE

+ 111
WITH QONE network
0,5
0,5
0,5
000
000 100
100
100 200
200
200 300
300
300

ROLE OF DC LINK AS LIMITED EXCHANGE OF REAL TIME CONTROL

SOURCE OF REACTIVE REACTIVE POWER WITH ON THE ARC CURRENT
POWER TO THE FURNACE THE MV NETWORK BEHAVIOUR
3

Power factor
by acting onto the copper bars of the feeding line Thanks to a less installed apparent power, 1
The layout of the new Q-ONE feeding system a consistent process energy saving is easily
is chosen and designed to limit the impact onto achievable (estimated in about 10%) with 0.8
the existing electrical and mechanical equipment. remarkable and substantial economical benefits.
0.6
Q-ONE equipment features Return of investment
> Reduced global power with respect to the In the light of the above, the ROI for a complete 0.4
equivalent furnace transformer; economical feedback is variable from country to
> Suitable arrangement of vector groups to country and can be estimated to be between
0.2
highly compensate harmonics; 9 to 24 months.
> High flexibility by handling unbalanced loads. 0
> Solution studied to keep AC furnace in Power factor 4 Power factor Time
1 Q-ONE EAF Power factor
operation with existing mechanical part; Transformer EAF Power factor
> High modularity inside a single phase-module
0.8
and within the whole valve;
> Suitable current redundancy; 0.6
> Hi flexibility by settling the output voltage;
> Easy maintenance and component 0.4
repleaceability (equipment components
available on the market) 0.2
> High level of safety by disconnecting and
grounding the furnace load during maintenance; 0
Time
> High flexibility by disconnecting single Q-ONE EAF Power factor 4
modules of Q-ONE in case of fault. Transformer EAF Power factor

Q-ONE maintenance
The Q-ONE system with its installation was
designed with utmost care to ensure simple
removal of the inverter and converter units, thus
guaranteeing easy inspection and maintenance of
the main components.

Q-ONE savings
With the adoption of Q-ONE power converters to
feed an Electric Arc Furnace, a consistent reduction
in electrode consumption can be expected,
estimated to be around 20%, as well as a drastic
reduction in power on time, about 10%.

5
 benefits & savings

PERFORMANCE SAVINGS OPERATIONAL BENEFITS

>10% > 20% > 10% >10% HI-SPEED HIGHER VERY LOW TOP
OVERALL ELECTRODE POWER-ON NOISE CONTROL FURNACE NETWORK RELIABILITY
PROCESS CONSUMPTION TIME REDUCTION OF VOLTAGE POWER FLICKER DESIGN
ENERGY (AT CONSTANT & CURRENT FACTOR MODULARITY
SAVINGS LEVEL)

INSTALLATION SAVINGS (due to unrequired equipment) MAINTENANCE AND INSTALLATION BENEFITS

SERIES EAF SVC FURNACE LOW IMPACT HIGH LEVEL EASY REMOTE
REACTORS TRANSFORMERS STATIC VAR BREAKER ON EXISTING OF SAFETY MAINTENANCE CONTROL
COMPENSATOR ELECTRICAL OPERATIONS VIA WEB
EQUIPMENT
DANIELI HEADQUARTERS DANIELI DANIELI AUTOMATION
Via Nazionale, 41 Via Bonaldo Stringher, 4
33042 Buttrio (UD) Italy 33042 Buttrio (UD) Italy
Phone +39 0432 195 8111 Phone +39 0432 518 111
www.danieli.com www.dca.it
[email protected] [email protected]

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