MELT EXPERTNEXT GENERATION ELECTRODECONTROL SYSTEM FOR ELECTRIC ARC
AND LADLE FURNACESMELT EXPERT – THE SUCESSOR OF ARCOS AND SIMELTCUSTOMER-ORIENTED USER INTERFACE

Melt Expert has been developed based on more than 35
years of experience with well known Arcos and Simelt
Electrode Control Systems. The new system unifies theadvantages of the previous solutions. New features likeKPI indication, plant monitoring, customer orientatedinterfaces as well as sophisticated control strategies ensure
most efficient production.

Target group orientated screens provide conditioned
information for different user needs like melt shop
management, electrical / mechanical maintenance,operators, etc. Designated screens support optimizationand parameter tuning for process experts. Regularly
revisions are simplified by a special maintenance mode.

OPERATION DATA PROCESSING AND KPI EVALUATION
A novel touch screen design allows simple and fast accessto process relevant data and displaying key values such as
actual consumption figures, melting time, regulation quality
etc. in the form of bench mark reports. Should there bea significant deviation from normal process parameters,
related information comes alive and will be indicated.
ON BOARD PLANT DIAGNOSTICS
Acquired data from hydraulics, mechanics and electrics is
put in relation to actual operating conditions. In this way
the electrode control system itself and its auxiliary systems
are permanently monitored.
So called health checks are performed automatically in
regular intervals in which the functionality of measurement
loops and output circuits are verified without disturbing
the process. Continuous signal collection in combination
with long-term-trend analysis allows the detection of shifts,deviations and creeping in malfunctions in a very earlystage with the aim to predict a possible event or damage,before it happens.

ENHANCED CONTROL ALGORITHMS FOR INCREASEDEFFICENCY
Based on actual process conditions, control parameterssuch as set points or controller gains are automatically
adapted by the system. Arc length will be modified
according to process needs. This results in a higher melting
efficiency and reduced energy consumption.
A new algorithm is avoiding arc extinction and increaese
the power input during boring phase.
An integrated loop gain linearization model transforms
individual mechanical furnace characteristics and uniforms
the control loops. Thus the parameter setup will be
simplified which results in faster performance run ups andless time needed for optimization.
Standard state of the art protection functions are included
as well as more advanced modules like countermeasuresagainst electrode oscillation.

primetals.com

HMI of Melt Expert

OPTIONAL TECHNOLOGICAL PACKAGES
For fully automated process control additional packages
like foaming slag control, melt down control and thermal
furnace balancing are available.
NEW HARDWARE ARCHITECTURE AND PRECISE DATAACQUISTION
Melt Expert is based on an embedded controller platform,
in which the system is split in a PLC part and a PC part.
This new concept unifies the advantages of both platforms
concerning flexibility, robustness and computing power,
which is necessary for fast and complex calculations as wellas high dynamic HMI.
Control signal handling is done within the PLC part whichsimplifies the integration into the automation environment.
Intelligent signal interface modules ensure very fastand accurate data sampling with on-board signal preconditioning.

Primetals Technologies
Austria GmbHA joint venture of Mitsubishi Heavy
Industries and partners
Turmstrasse 44 | 4031 Linz | Austria
primetals.com
Order No. T02-4-N203-L2-P-V3-EN
Printed in Linz | © 02.2020

MAIN BENEFITS• Reduced energy consumption and increased
melting efficiency due to auto-adaptive
regulation algorithms• Higher productivity ensured by automatic
melting profiles and process parameter
adaptation• Highest reliability due to main focus onrobustness and operational safety in anindustrial environment• Ensured process quality due to target grouporientated screens and highly sophisticateddata recording and evaluation• Amortization within less than nine months

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of performance based on estimates and assumptions which have not been verified. It is no representation, does not constitute and/or evidence a contract or an offer to enter into a contract to any extent and is not binding upon the parties. Any obligation to provide
and/or demonstrate respective characteristics shall only exist if expressly agreed in the terms of the contract. These estimatesand assumptions have to be analyzed on a case-to-case basis and might change as a result of further product development.
Primetals Technologies excludes any liability whatsoever under or in connection with any provided information, estimates andassumptions. The provided information, estimates and assumptions shall be without prejudice to any possible future offer and/orcontract. Any use of information provided by Primetals Technologies to the recipient shall be subject to applicable confidentiality
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Ltd.