Rapporten behandlar Kandidatarbete i maskinteknik som utfördes mot Outokumpu Stainless AB, Avesta. Syftet med arbetet var att optimera placeringen för kalkinjektionen som inte sitter optimalt placerat ur ett processoptimeringsperspektiv. Målet var att utveckla placeringen och nyttjandet av kalktillsatsen i ungen, det genom att ändra designen av valvstrukturen och kylpanelen där injektionen satt ursprungligen. Positionen för kalkinjektionen i ljusbågsugnar är normalt sett placerad i hotspotten, området i ugnen där elektronerna är närmst väggen och ger mest slitage på tegelinfodringen. För att hitta en mer optimal placering och lösning studerades befintliga placeringar hos Best in Practice, Tornios och Calverts designs anläggningar, men även ett flertal besök på Outokumpu genomfördes för att skapa en tydligare bild av processen och valvkonstruktionen. En viktig del för den här typen av projekt är konstruera lösningar och att applicera dessa på valvet med hjälp av simuleringar och 3D-modeller. På det sättet går det snabbt att testa lösningar och ge en indikation om det är något som är genomförbart eller inte. Lösningar som togs fram presenterades för Outokumpu som tog beslut om att beställa de nya kylpanelerna med den utformningen som togs fram under projektet. / This report will process a master’s thesis in mechanical engineering in cooperation with Outokumpu Stainless AB, Avesta. The purpose with this work was to optimize the position for the chalk injection which, today, is not optimized from a process position view.  The goal was to develop a position and utilize the chalk supplies and this by changing the design in the vault structure and the cooling panel where the injection originally was placed.  The position of the chalk injection in the arc furnace is normally placed in the hotspots, this is the area in the furnace where the electrodes is closest to the wall and affects the most in terms of wear of the brick lining. To be able to find a more optimal position other chalk injection designs were studied that is already in use, for example in Best in Practice, Tornios and Calverts. There were also visits at Outokumpu in Avesta to create a clearer picture of the process and the vault construction.  One important part for this project was to construct a solution and then apply this on the vault with help from a simulation and 3D-models. To be able to do this Inventor was used, the same program that Outokumpu uses. By using Inventor you can easily try out different solutions and it will give an indication if it is possible to move on with this idea or not. The solutions that were established were presented to Outokumpu who then took the decision to move on with the idea and order the new cooling panel in the design that was created throughout the project.

During the three decades, the torsional impact on turbine-generator sets due to power system disturbances has been extensively discussed in many research works. However, most of them are focused on the fatigue damage of turbine shafts due to large-signal disturbances. For example, network faults occur. Obviously, the torsional effect subject to small-signal disturbances has not received much attention. In fact, although the small disturbances would not immediately damage the turbine mechanism, the cumulative long-term damaging effects may not be negligible under certain circumstances. Many operating conditions in power systems may lead to small disturbances on blades; for examples, shedding loads, switching transmission line, resetting control system parameters, and harmonics etc. Nevertheless, others only cause short-term or transient non-resonant disturbances occasionally except the power system subharmonics which could results in electro-mechanical resonance. Therefore, two types of subharmonics in power systems are proposed so as to investigate the toque impact and long-term fatigue life expenditure in turbine shafts and blades. Firstly, from the steady-state disturbance viewpoint, the long-term cumulative fatigue estimation based on the three-year project of the GE Co. shows that there are potential damages for both the shafts and the blades of the nearby generators caused by the subharmonic excitations of the HVDC link. The fatigue life sensitivity works are also carried out to provide the recommendations for the safety operation. The optimal damper type and disposition scheme for depressing the resonant torque and prolonging the turbine lifetime is consequently motivated, which is based on participation factor of linear systems with the electromechanical analogy. The effectiveness of this scheme on suppressing vibration torque arising from network faults is also satisfying. In addition, the authors propose the new electromechanical supersynchronous resonance phenomenon for the turbine-generators near the inverter station owing to asymmetric line faults near the rectifier station. Secondly, the dramatic real and reactive power consumption during the melting period of an electrical arc furnace load. The voltage flicker pollution is mainly caused by the reactive power fluctuation while the stochastic subsynchronous oscillation in turbine mechanism is excited by the electromagnetic torque of the subsynchronous frequency which is induced by the real power fluctuation. Such a small stress imposed on the low-pressure long turbine blade combined with its evitable corrosive environment contributing to the corrosion fatigue effect. Although the voltage flicker severity at the point of common coupling is still within the limit, the blade may have been damaged from the long-term corrosion fatigue life expenditure estimation. In other words, the conventional voltage flicker limit established to make human-eye comfortable might not protect the blade from damaging risk. The long-term influence resulted from the electric arc furnace loads cannot always be neglected. It is necessary to take care of the blade material intensity and operating environment. If there is the potential of blade damage, one has to strengthen the output capacity at the power plant or separate the peak load durations among the steel plants to limit the over-fluctuation real power of the generator.

In this research work, two new flickermeters are proposed to estimate the light flicker caused by electric arc furnaces (EAFs) where the system frequency deviates significantly. In these methods, analytical expressions of the instantaneous light flicker sensation are obtained beginning from a voltage waveform and these expressions are used to obtain a flicker estimation method based on the IEC (International Electrotechnical Commission) flickermeter. First method is a spectral decomposition based approach using DFT to estimate the light flicker. The leakage effect of the DFT algorithm due to fundamental frequency variation is reduced by employing spectral amplitude correction procedure around the fundamental frequency. Second method is a Kalman filter based approach, in which the frequency domain components of the voltage waveform are obtained by Kalman filtering. Then these components are used to obtain the light flicker. Since the frequency decomposition is obtained by Kalman filtering, no leakage effect of the DFT is involved in case of frequency deviations which is an important advantage. Both methods are tested on both simulated data and field data obtained from three different EAF plants where the flicker level and frequency variation is considerably high. The comparison with the digital realization of the IEC flickermeter shows that the methods are successful in estimating light flicker with low computational complexity. The methods are especially useful for conditions such as disturbances and subsequent system transients where the system frequency deviates significantly, since the methods avoid the need for online sampling rate adjustment to prevent the DFT leakage effect.

A method of producing steel that is not used in Sweden today is direct reduction using natural gas, a method which could has enormous potential in the future of steelmaking. Historically, steelmaking prioritized productivity and profitability. However, other aspects such as safety, sustainability, and environmentally friendliness have become increasingly important to Swedish steelmakers. This study evaluates the usage of natural gas to  directly reduce iron ore into the porous form known as iron sponge, then finally processing that sponge into crude steel. The technology available today is assessed through a literature review, then two calculative data-based model: using DRI sponge in a traditional integrated steelmaking line or replacing steel scrap with it in an electric arc furnace. While this technology is used in many regions where natural gas is plentiful, it has not yet been used in Sweden. Now, when the Swedish natural gas network is expanding and the vehicular transportation of liquid natural gas is becoming more and more viable, it is a prime situation to evaluate direct reduction in Sweden. While models require assumptions and estimations, they suggest that DRI will absolutely be a viable option in the years to come. Integrated plant operators can reduce their immense carbon emissions for a reasonable price, while DRI sponge melting in an electrical arc furnace can either help steelmakers escape the volatile scrap market or be used to replace the blast furnace as a whole in the future. / En metod för att producera stål som inte används i Sverige idag är direkt reduktion med hjälp av naturgas, en metod som har en enorm potential i framtida ståltillverkning. Historiskt har ståltillverkningen prioriterat produktivitet och vinst, men säkerhet, hållbarhet, och miljövänlighet har blivit områden mer och mer viktiga för svenska ståltillverkare. Den här studien utvärderar användningen av naturgas för att direkt reducera järnmalm till den porösa formen känd som järnsvamp, och sen bearbeta den till primärt stål. Teknologin som flnns idag utvärderas genom en litteraturstudie, vars data beräknas till två scenariomodeller: användningen av järnsvamp i ett traditionellt integrerat stålverk eller genom att ersätta stålskrot med järnsvamp i ljusbågsungen. Den här teknologin används redan idag i regioner där naturgas är lättillgängligt, men har hittills inte använts i Sverige. Men nu när Sveriges naturgasnät byggs ut och fordonstransporterad flytande naturgas blir mer och mer kostnadseffektiv så är det lämpligt att utvärdera direkt reduktion i Sverige. Modellerna kräver antaganden och uppskattningar, men de pekar på att direkt reducering av järnmalm kommer att vara en genomförbar metod för ståltillverkning i en nära framtid. Integrerade masugnslinjer kan minska sina enorma koldioxidutsläpp till ett rimligt pris, och järnsvampssmältning i ljusbågsugn kan hjälpa ståltillverkare att undanfly den instabila stålskrotsmarknaden eller användas för att helt ersätta masugnsproduktion i framtiden.