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This article is the story of our experiences developing and running the iWRS AI control system.The Early YearsBy 1995, the AI controls team had been working with several groups in the Crew and Thermal Systems Division (CTSD), building Al control systems in support of CTSD''s investigations in advanced life support (ALS). In 1995, they put a man in an airlock linked to a 10-foot-diameter chamber full of wheat (Laifook and Ambrose 1997). For 15 days, the man lived, worked, and exercised in the chamber as the wheat crop took in his carbon dioxide and produced oxygen for him. The control system--our first for ALS--monitored and provided caution and warnings for the climate and nutrient environment of the wheat crop.

Although this article started with a general overview of the iron and steel industry, we will refer only to one process for the rest of this feature, a gray iron foundry using an electric arc furnace. We will see how important brick and refractory are and why everyone should pay attention to their brick and refractory designs and installations.History and Background of the Electric Arc FurnaceThe electric arc furnace (EAF) has been around since the early 1900s and is primarily used to produce high quality alloy steels. EAFs have refractory-lined steel shells and vary ill size from only a few feet in diameter to twenty feet or more. The bottom, or hearth, of the furnace is dished to hold the metal charge. The vertical side walls include one or more doors and a tapping spout for removing the melted charge. The roof over the furnace is dome-shaped, and incorporates two or three openings near its center for the admission of electrodes into the furnace. The roof is usually detachable and is lifted off or turned aside for charging. The whole furnace structure is tilted forward and backward for slag skimming or tapping. The furnace capacity will depend upon the size of the furnace and can be less then one ton per charge to up to eighty-five tons per charge.

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