A system and method for monitoring consumption of graphite electrodes during the operation of an electric arc furnace (EAF) uses machine vision cameras operatively communicating with a computer processor. The system can determine, track, manage, and optimize the consumption of the graphite electrodes in real time. Electrode consumption is determined for each EAF heat by measuring the length and tip diameter of the electrode. The length and tip diameter are used to determine the electrode consumption amount using a consumption model. Measured hydraulic pressure within the EAF correlating with a known electrode weight can also be used to determine electrode consumption and correlated with the model calculation. Butt loss can also be determined based on the machine vision measured lengths of the electrode and/or based on the hydraulic pressure. The calculated electrode consumption amounts are also stored in a database and correlated to other measured EAF parameters for multiple EAFs.

A control system for a vacuum arc remelting (VAR) process for a metal includes a direct current (DC) power source, a ram drive, voltage drip short sensor, and a controller, which includes a processor. The drip short sensor may be configured to measure a drip short frequency of the electric arc over a period of time. The controller is configured to determine a real time arc gap length between the electrode tip and the melt pool based on a correlation between the drip short frequency and arc gap length. The controller is further configured to control power input to the electrode by the DC power supply by determining an input power level to input to the electrode based on the real time arc gap length, the input power level configured to generate a desired arc gap length, by the DC power supply, at the input power level.

A control system for a vacuum arc remelting (VAR) process for a metal includes a direct current (DC) power source, a ram drive, voltage drip short sensor, and a controller, which includes a processor. The drip short sensor may be configured to measure a drip short frequency of the electric arc over a period of time. The controller is configured to determine a real time arc gap length between the electrode tip and the melt pool based on a correlation between the drip short frequency and arc gap length. The controller is further configured to control power input to the electrode by the DC power supply by determining an input power level to input to the electrode based on the real time arc gap length, the input power level configured to generate a desired arc gap length, by the DC power supply, at the input power level.

An electric arc furnace (EAF) including a set of mast hydraulics, a current transformer, a voltage transformer, a legacy control system and a set-point modifier. The legacy control system is in control of the set of mast hydraulics of the EAF, and receives information from the current transformer relative to current being supplied to the EAF and from the voltage transformer relative to voltage being applied to the EAF. The legacy control system using a set of set-points for the control of the set of mast hydraulics, the voltage and the current of the EAF. The set-point modifier communicates with the legacy control system, and executes the steps of: evaluating a cost function of key performance indicators of a previous heat of the EAF, the key performance indicators including electrical energy use and/or electrode consumption; and altering the set of set-points dependent upon the cost function.

A control system for a vacuum arc remelting (VAR) process for a metal includes a direct current (DC) power source, a ram drive, voltage drip short sensor, and a controller, which includes a processor. The drip short sensor may be configured to measure a drip short frequency of the electric arc over a period of time. The controller is configured to determine a real time arc gap length between the electrode tip and the melt pool based on a correlation between the drip short frequency and arc gap length. The controller is further configured to control power input to the electrode by the DC power supply by determining an input power level to input to the electrode based on the real time arc gap length, the input power level configured to generate a desired arc gap length, by the DC power supply, at the input power level.

A control system for a vacuum arc remelting (VAR) process for a metal includes a direct current (DC) power source, a ram drive, voltage drip short sensor, and a controller, which includes a processor. The drip short sensor may be configured to measure a drip short frequency of the electric arc over a period of time. The controller is configured to determine a real time arc gap length between the electrode tip and the melt pool based on a correlation between the drip short frequency and arc gap length. The controller is further configured to control power input to the electrode by the DC power supply by determining an input power level to input to the electrode based on the real time arc gap length, the input power level configured to generate a desired arc gap length, by the DC power supply, at the input power level.