A hybrid simulation model of AC electric arc furnace

Li hongru 1, Zhao haoyi 1, Li fangyan 1, Qiu bo 2

1. College of Information Science and Engineering of Northeastern University, Shenyang, 110819
E-mail: lihongru@ise.neu.edu.cn
2. Shenyang Weizhong Revolving Machinery Co., Ltd., Shenyang 110013, China
E-mail: qiubo0601@163.com
Abstract: A hybrid simulation model of AC electric arc furnace is proposed, which is useful for both power quality
analysis and electric arc control research. The lack of knowledge of quantifying expression due to the complex nature of
the AC electric arc system was overcome by parameter estimation. Combined the advantage of two existent typical
electric arc model, a hybrid simulation model of AC electric arc furnace was deduced. A novel formula between the arc
voltage and arc length and arc current was put forward to. In order to get the concerned parameters of the AC electric arc
model, simulation analysis and numerical value calculation were used on the basis of theoretical deduction. At last, the
proposed model was simulated in Matlab. Comparing the simulated results with the measurement data, it is shown that
the model can accurately represent the AC electric arc furnace process. The developed model is valid and easy to use.
Key Words: AC electric arc furnace, Hybrid simulation model, Parameter estimation

power in the fundamental frequency, which is not always

true. Reference [5] provides a harmonic domain solution of
nonlinear differential equation. But it is based on an
experimental formula. Random process method shown in
[6] is based on the stochastic nature of the electric arc V-I
characteristic. Nevertheless, the model is divorced for lack
of any consideration of the number of inputs of the arc
model.
At the present time, most of the electric arc models are so
far from real processes of the electric arc that they are not
the realistic electric arc model. Hence, this paper presents a
hybrid arc model. Hence, following and inheriting those
existent models at present three tasks in this papers are
made: (1) According to those qualitative expressions in
one existent model the task of quantifying expression has
been done to make it analyzed without assuming those
variables in reality to be constant as a initial condition; (2)
Judging from the differences between the actual and
simulation data and referring to those qualitative
improvements to the other existent model, this paper adds
parameter factor to optimize, and after a series of
simulation process in which the exact number of optimized
parameter is determined in a optimum way. In the final, the
correction of the optimized expression is proven in the end;
(3) MIMO arc model is turned into SIMO by combining
the two improved model into the hybrid arc furnace model.
Finally, the present model is validated by the comparisons
with actual data.

INTRODUCTION

Electric arc furnaces are used in todays steel industry;

however, many utilities are facing the problem caused by
the arc furnace load. An accurate three-phase arc furnace
model is needed for the purpose of harmonic analysis and
flicker compensation. Owing to the factors affecting the
arc furnace operation, the description of an arc furnace
load depends on the following items: arc voltage, arc
current and arc length. Historically, there have been many
methods of electric arc modeling. In general, the existing
electric arc models may be classified as below in detail:
1) V-I characteristics method
2) Time domain equivalent nonlinear circuit model
3) Harmonic voltage source model
4) Harmonic domain solution of nonlinear differential
equation
5) Random process method
The V-I characteristic method given in the [2] is simple
and direct. The relation between voltage and current can be
obtained based on a piece-wise linear approximation of the
rated V-I characteristic of electric arc. But it can only
satisfy a certain operating condition. Reference [3]
presents a time domain equivalent nonlinear circuit model.
The circuit is proposed on the basis of the simplification of
an electric arc V-I characteristic. It is a primitive model
and the time-varying characteristic of arc furnace loads can
be neglected. Harmonic voltage source model mentioned
in [4] first applies Fourier transform to the arc voltage
waveform to obtain its harmonic components, and then the
arc current harmonic components calculated through the
arc voltage harmonic components. In this model, it is
assumed that the arc furnace load draws the maximum

2.1 Deduction of the AC electric arc-resistance model

Although qualitative arc model is well known especially in
China, it does not give the specific expression for each
parameter. In order to better expand the application area of
his arc model, several assumptions are needed to make:

This work is supported by National Nature Science Foundation of P. R.

China Grant # 61004083.

c
978-1-4577-2074-1/12/$26.00 2012
IEEE

ELECTRIC ARC MODEL

188

(1) The radius of arc is constant

The variation of the radius of the arc can be ignored in
many cases [7].
(2) The temperature of arc column is even
When proceeding steel production process, the magnitude
of temperature in the arc column often varies little [8].
(3) Quasi-neutrality is assumed
In terms of the theory of electromagnetic fields, the
electromagnetic field is approximate to the constant.
Namely,

Where, 0 is constant, a is coefficient. Furthermore,

based on (9) and (10), to conclude,

(1)
(2)
Basically speaking, the characteristic of AC arc can be
described as without considering some ignorant factors as
follows [9].

Where, T1 is the highest temperature of the arc column,

JG
E = 0
E = const

cp

T
= (T ) E 2 enct
t

(3)

And combined with ohm's law

r0

i (t ) = 2 (T ) E d

(4)

Where r is specific gravity, c p is specific heat at constant

pressure, is coefficient of thermal conductivity, enct is
the balance of radioactive energy, T is temperature, (T )

is conductivity, E is electric field intensity, r0 is radius of

arc column. Solving expression (4), we can conclude,

i (t ) = r02 (T ) E

(5)

And then

E=

1
i (t )
(T ) r02

(6)

R(T ) = CLe
Where, C =

T = T0 +

T1 T0
[1 cos(2t + + D)]
2

B = (T1 T0 ) / 2a , the resistance of the arc column can be

written as:
1

R(i, t ) = CLe{ A+ B[1cos(2t + + D )]}

that R = Rmax = CLe a / T0 .

B reflects the influence of the variation of arc temperature.
C is coefficient of proportionality reflecting the influence
of radius of the arc column.
D reflects the influence of thermal inertia of the arc
column.
When i = I 0 sin(t + ) is assumed, and then with =0,

(7)

cos(t ) =

T
i (t )2
=
enct = f (i (t ), T )
t c p (T ) (T ) 2 r04
u (t ) =

L
i = R(T )i (t )
(T ) r02

= 0 e

a
T

i (t

(14)

TP
)
4

I0

cos(2t + D ) = cos D (1 2

2sin D

Usually when we consider the influence of (T ) , arc

pressure is deemed to be constant with which we can
conclude that is in proportion to x which is degree of
liberation[10]. Therefore, Sahaionization formula can be
described as:

i (t )
I0

(15)

Where TP is the period of the extrinsic motivation. And

then,

(8)

(9)

(13)

A reflects the influence of the minimum arc temperature on

the resistance of the arc.
When A + B[1 cos(2 t + + D )] = 0 , conclude

sin(t ) =

L is arc length, u (t ) is voltage of the arc column.

Combine (3), (4), (5), (6), (7) together and conclude,

(12)

T0 is the lowest temperature of the arc column, is

frequency of extrinsic motivation, is phase angle lagged
by extrinsic motivation when the current of the arc go
through the zero point. The extrinsic motivation is
T
assumed as initial phase angle being zero. Let A = 0 ,
a

u (t ) = Edz
i (t )
L
dz =
i (t )
2
(T ) r02
0 (T ) r0

(11)

described as [11],

L
0

a
T

is constant. Whats more, T can be

0 r02

To integrate (6) along the direction z,

i 2 (t )
)
I 02

(16)

TP
)
4 = f (i (t ), i(t TP ), D)
2
4
I0

i(t )i (t

As a next step,

R (i, t ) = C L e

{ A + B [1 f ( i ( t ), i ( t

TP
), D )]} 1
4
(17)

Which not only reflect the influence of thermal inertia, the

variation of temperature, the zero point of arc current on
the arc resistance, but also the influence of current
waveform on the arc resistance.

(10)

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Figure 1 shows the difference between the actual V-I curve

and its original (not rectified) R.C Dugant linear model
curve.

(T )

=e

a(

1 1
)
T' T

(20)

'

1
(T )
and then
Let x = ( ) , f (T ) =
' T

T
'

f (T ) = eax

(21)

Let ln f (T ) be y (T ) least squares approximation, and

then

To solve

n
{[ y (Tk ) ax(Tk )]x(Tk )} = 0
k =1

(22)

Fig.1 U-I characteristic of the arc

The original R.C Dugant arc furnace model can be

approximately represented by the u = + L where
the L represents the arc length, is the constant that is the
sum of voltage drop in anode and cathode, and is the
constant that is the voltage drop per unit length. From the
Fig.1, we can conclude that there is something
inappropriate with this model especially at the point of
ignition voltage and extinction voltage, with the intention
of rectifying and making the well-known equation widely
practical, some relative assumptions for advancing the
practicality of the model [12, 13] are offered but no one has
proven its correction and combined them. Hence,
grounded on the existent but not mature conclusions and
two unproven assumptions, the possible correct equation is
given as follows:

u = + L + KI
(18)
100, prophase

Where = 40, = 38, metaphase , K = const

10, anaphase

a=

y (Tk ) x(Tk )

k =1

x(Tk )

And next

(T ) = ' eax

(24)
In terms of some relative data [14], based on expression
(23) to conclude,

a 3.323 104 ( K 1 )
And calculate the (T ) .
(2) The estimate of T0 and T1

In the real computer calculation, T0 is set as 7000K due to

the speed restriction of computer. Because the current in
the arc furnace exceed far 2000A [15], we can assume that,

(T1 ) = I

, in order to indicate in an approximate

as = o e
manner, we can write as follows:

(T ) = 0e

'

'

a
T

When T = T ' , (T ' ) = , Secondly

(T1' ) = I '

(27)

(T1 )
I
= '
'
I
(T 1 )

(28)

And then

Namely,

a(

1 1
)
T1' T1

I
I'

(29)

Finally solve

T1 =
(19)

1
1
1
I
ln '
'
T1 2a I

(30)

(3) The estimate of D

In terms of relative data [16], we can get
(4) The estimate of C0

190

(26)

Where I is the effective value of the arc current. As for I ' ,

the conductivity of arc column can be represented

a
T

(25)

'

AC electric arc-resistance model

k =1

2.2 Estimation for the concerned parameters of the

(1) The estimate of A and B
When pressure p is constant, and also is c p , and as a result,

(23)

D = 15 5 I

2012 24th Chinese Control and Decision Conference (CCDC)

(31)

The equivalent LTI resistance can be made with the

parameters of the short net and the average power factor of
arc furnace determined,

cos =

R+r
( R + r )2 + ( L' )2

(32)

L' is one-phase equivalent inductance, r is one-phase

equivalent resistance. And then
'
R = Lctg
r

(33)
Let R be the average value of the arc resistance, namely

R=

1 TP
1 TP
{ A+ B[1 cos(2t + D )]}1
R(i, t )dt =
dt (34)

CLe
TP 0
TP 0

In order for convenience of calculation the period TP is

divided into N equal parts, to get

1
R
N

C0e

{ A + B [1 cos( 2

TP
k + D )]} 1
N

(35)

k =1

Based on TP = 2 , we can conclude

C0

N ( L 'c t g r )
N

{ A + B [1 c o s (

4
k + D )]}1
N

(36)

k =1

When initial I , A , B , cos , X , r , T1' , I ' are assigned

with various kinds of value, the expression (34) about R
can be verified to be totally correct through the following
simulation Fig.2 showing the typical V-I characteristic of
the arc.

Fig.2 the U-I curves when initial I , A , B , cos , X

, r , T1' ,

I ' are

assigned with various value

(5) The estimate of K

The rectified parameter K mentioned in [17] is merely
qualitative but not quantitative which is deemed to make
the arc voltage expression as u = + L + KI , So the
simulation tool Simulink in the Matlab we can use can
make effect in determining the exact value of the K on
the basis of the arc characteristic hysteresis curve,
besides that, it is efficient and reasonable to simplify the
number of
input of the arc model with combining the first quantitative
model mentioned above with u = + L + KI to realize
an advanced arc model, the input of which is merely arc
length.

D1
(1 + sin t )
2
[17], where D1 is the maximum value of the arc length,
L0 is the initial length of arc, is the frequency of
sinusoidal signal.
First of all, we should evaluate the rough range of the value
of the K , we can find that only if when K 1.5 the curve
is close to the ideal hysteresis curve through the Simulink.
Secondly, a series of the value of K are set, this only take
three value ( respectively K = 0.8,0, 0.8 ) for example.
When K = 0.8 , the I-U characteristic curve of the arc is
shown in Fig.3.
The arc length expression is L(t ) = L0

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When K = 0.8 , the I-U characteristic curve of the arc is

shown in Fig.5.

Fig.5 the I-U curve when K = 0.8

Fig.3 the I-U curve when K = 0.8

When K = 0 , the I-U characteristic curve of the arc is

shown in Fig.4.

u = + L + KI

100, prophase

Where = 40, = 38, metaphase, K = 0.8

10, anaphase

Fig.4 the I-U curve when K = 0

SIMULATION RESULTS

In order to validate the accuracy of the model, the

three-phases electric circuit is established in a Simulink
model as shown in Fig.6 in which the arc length is the sole
input for arc model in the system, the differences of the
three phases of which is the 120 degrees of lagging angle
for either two of the three phases A, B, C. So that only one
phase research is needed.

Fig.6 the Simulink picture of three-phases electric circuit

For analogy and simplification, phase A, in which the arc

length is the sole input for arc model in the system, is
extracted for research on comparison between actual value
and simulation value. The proposed model is simulated in
a single-phase circuit as displayed in Fig.7.

Fig.7 Simple-phase equivalent electrical circuit

192

(37)

2012 24th Chinese Control and Decision Conference (CCDC)

Diagram of the arc furnace transformer secondary

windings. For the simulation, the actual circuit parameters
and the parameters of electric arc model can be given as
below: U PhaseA = 243V , X d = 0.003 , rd = 0.0004 ,
.

[1]

[2]

The simulation initial conditions are i = 0 and g = 1 .

[3]

[4]

[5]

[6]

(a) Arc voltage

[7]

[8]

[9]

[10]
(b) Arc current
Fig.8 comparison between actual data and simulation data

The data obtained by the proposed simulation model and

the actual data which are different from the mentioned
sample data and are used to test, are compared in Fig.8
when the arc length is different. By the provided results the
waveforms are very similar. Hence, the proposed electric
arc model can be accurate.

CONCLUSIONS

[12]
[13]

[14]

A new hybrid electric arc model is developed in this paper

which follows and inherits those existent models at present
three tasks in this papers are made: (1) Based on the
qualitative conclusions, quantified arc model is finished
and verified; (2) Based on the existent arc model, which
have potential problem when seen from the difference
between the practical and theoretical data, the rectified
factor is added into the arc model expression; (3)
Combined with the two rectified arc models mentioned
above, the hybrid electric arc model is finished. The hybrid
model provides voltage and current waveforms as well as
arc characteristics that are similar to those observed in
actual plants, which provides its validity.

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