Electric arc furnace electrode consumption analyzer

In an electric arc furnace for heating a charge contained therein including at least one electrode projecting into the furnace and electrode support structure for moving the electrode in a direction along a path towards and away from the charge, the improvement comprising:

• a sensor for detecting the position of the electrode support structure with respect to an initial starting position in which an electric arc is generated from the electrode;
• a processor for calculating a distance of electrode support structure travel from the initial starting position and a rate of electrode consumption;
• and
• a signal generator for generating an alarm signal when one of said travel distance and said electrode consumption rate are equal to or larger than an associated one of a predetermined threshold travel distance and a predetermined threshold rate of electrode consumption, wherein said alarm signal is indicative of an excess electrode consumption condition for a given heat.

In an electric arc furnace for heating a charge contained therein including at least one electrode projecting into the furnace and electrode support structure for moving the electrode in a direction along a path towards and away from the charge, the improvement comprising:

• a sensor for detecting the position of the electrode support structure with respect to an initial starting position;
• a processor for calculating one of a travel distance of the electrode support structure from the initial starting position, which is indicative of the amount of electrode consumed, and a rate of electrode consumption;
• a signal generator for generating an alarm signal when one of said travel distance and said electrode consumption rate is at least equal to an associated one of a predetermined threshold travel distance and a predetermined threshold rate of electrode consumption, wherein said alarm signal is indicative of an excess electrode consumption condition for a given heat;
• and
• a power reducer for automatically decreasing electrical power supplied to the electrode in response to said alarm signal and as a function of a magnitude of the excess electrode consumption condition.

A method of heating a charge in an electric arc furnace that includes at least one electrode projecting into the furnace and electrode support structure for moving the electrode in a direction along a path towards and away from the charge, said method comprising the steps of:

• determining a position of the electrode support structure with respect to an initial starting position;
• calculating one of a support structure travel distance and a rate of electrode consumption;
• and
• generating an alarm signal when one of the travel distance and the electrode consumption rate is at least equal to an associated one of a predetermined threshold travel distance and a predetermined rate of electrode consumption, wherein said alarm signal is indicative of an excess electrode consumption condition for a given heat.