Slag, an unwanted byproduct in steel production, has the potential to adversely affect steel quality and lead to expensive production costs.
Detecting and analysing slag's composition and quantity in the steel melt is critical. This information empowers steelmakers to take prompt control actions, ensuring the production of high-quality steel with minimal waste, ultimately enhancing the sustainability and efficiency of steel manufacturing processes.
Slag detection systems find applications in secondary steelmaking vessels such as Electric Arc Furnaces (EAF) or Basic Oxygen Furnaces (BOF), as well as in processes involving stainless steel, copper, platinum, and other smelting operations.
Continuous Slag Detection in Green Steel Production
Green steel plays a pivotal role in decarbonization efforts, as it offers a means to substantially reduce carbon emissions in the steel industry. It conserves resources, enhances energy efficiency, stimulates innovation and economic growth, and meets the increasing demand for environmentally sustainable products in a carbon-constrained world.
Continuous slag detection and precise process control are essential for identifying and monitoring slag during the early stages of production. This, in turn, improves steel quality, reduces energy consumption, and curtails emissions, including CO2.
Why Choose the AMETEK Land MWIR-640 SDS-Based System
In most slag detection applications, it is nearly impossible to consistently obtain clear and detailed images of the tap stream due to demanding environmental conditions characterized by smoke, hot process gases and particulates. However, this clarity is essential for reliable slag detection and cannot be achieved with long-wave LWIR based (8-14 µm) thermal imagers or systems.
The
new MWIR-640 SDS Thermal Imager Unit, with an advanced 3.9 µm spectral response, provides the clearest view through smoke, particles, and hot process gases available throughout the market. This breakthrough technology enables reliable and continuous slag detection, as well as additional freeboard level measurements in these processes.
Groundbreaking Benefits of the All-New AMETEK Land SDS System
The fully remotely accessible SDS System integrates the MWIR-640 SDS imager with a selection of optics, a robust industrial enclosure for continuous operation together with a slash shield and a sighting tube, a field Power Supply Unit (PSU) with the option for data fiber optic connections, and a workstation equipped with advanced thermal imaging and process control software, IMAGEPro, and the brand new IMAGEPro SDS V2 extension.
For specific field installations, various configurations are available upon request.
The IMAGEPro SDS V2 – The Intelligent SDS Control Center
IMAGEPro SDS V2 is an integrated component of the advanced
IMAGEPro thermal imaging software package. It serves as the primary remote monitoring control center for slag detection measurements, documentation, and process control providing fully remote access to the camera installation.
As the tapping process begins, the SDS software automatically detects and records a data log and generates a live graph. An intelligent stream tracking mechanism ensures reliable operation under typical installation conditions. When slag appears and surpasses an operator-defined threshold, an alarm is automatically triggered. The system is designed to provide accurate, real-time detection of steel/slag, independent of charge weight and without operator intervention.
Multi-Camera Use – Freeboard Detection Included in SDS System
An optional multi-camera license permits users to seamlessly integrate additional imagers into the system and software, allowing them to operate independently from the primary camera and the continuous slag detection system.
For instance, users can incorporate extra
MWIR-640 and
NIR-656/-2K industrial thermal imagers to capture real-time freeboard levels on-site. This comprehensive approach enables simultaneous recording, visualization, and control of both processes within a centralized application that is fully accessible remotely.
The All-New SDS System – Main System Benefits
Steel Temperature Measurement and Monitoring: Measures steel temperature throughout the tapping process.
Automatic Stream Identification and Tracking: Accurately identifies the stream and reduces background interference. Intelligent tapping stream tracking and background suppression ensure the highest reliability of the slag detection measurement.
Advanced Spectral Filtering: Provides the clearest thermal images and enables continuous slag and steel detection.
Multi-Imager Option: Secondary imager for stream position and freeboard level monitoring and control.
Multiple Communication Options: Improved connectivity through the use of the Open Data Interface for digital and analog interfacing.
IMAGEPro SDS-Based Process Control: Advanced IMAGEPro SDS thermal imaging process monitoring and control software, incorporating a full range of functions from a single source.
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