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SDS - Slag Detection System (SDS)

Slag Detection System (SDS)
The LAND Slag Detection System (SDS) uses a high-resolution thermal imaging camera to detect the transition between steel and slag during tapping. It delivers improved yields, higher-quality steel and reduced costly downstream processing, with the additional benefit of reduced ladle refractory wear.
Data is presented to the operator in real time, enabling informed decisions about the tapping process, and the system provides clear alarm notifications - so operators can act at exactly the right moment.

  • Overview +


    At the end of the tap, the levels of slag and steel rapidly reverse. Quick termination of the tap after the alarm has been triggered is necessary to prevent excessive levels of slag in the ladle. The SDS camera is purpose-built for this critical moment: it has been specifically designed to survive harsh operating conditions and uses a particular wavelength to reduce obscuration caused by smoke and fume, giving operators a clear view when it matters most.

    SLAG DETECTION SYSTEM AT A GLANCE

    SPECIFICATION DETAIL
    Temperature band Mid-temperature: 500 to 1800 °C / 932 to 3272 °F
    Wavelength Mid-wavelength (MWIR): 3.9 μm camera / MWIR-640-SDS
    Spectral response 3.9 μm
    Pixel resolution 640 x 480 pixels
    Max frame rate 60 fps / 7.5 fps
    Optics (FOV) 12° x 9° / 25° x 19°
    Interfacing Open Data Interface, Modbus TCP, Moxa I/O unit
    Software ImagePro-SDS
    The Road to Industrial Decarbonisation

    GREEN STEEL AND DECARBONISATION

    The LAND SDS supports the decarbonisation process in steel production through continuous process control and optimisation, energy savings and emission reduction — helping steelmakers move towards greener, more efficient operations.

    SUITABLE FOR A VARIETY OF APPLICATIONS

    SDS is suitable for operators of secondary steel making vessels — for example EAF and BOF — including stainless steel, and can also be used in other smelting operations such as copper and platinum. By adding further regions of interest (ROI) together with a secondary thermal imaging camera integrated into the system, optional features such as stream position or freeboard height can also be added, providing advanced process monitoring and control.

    PROVEN BENEFITS

    • Improved product quality: SDS has been demonstrated to improve operator response time and consistency at the end of each tap, typically reducing slag depths by up to 25% compared to traditional methods of stream monitoring.
    • Reduced downstream processing costs: by controlling slag carry-over, costly downstream processing time and materials can be reduced or eliminated, improving plant throughput, product quality and operating margins.
    • Reduced ladle refractory wear: a direct additional benefit of controlling slag carry-over.
    • Improved operator safety: an effective solution for monitoring and helping reduce slag carryover, supporting cost savings and safer operation.

    HOW AUTOMATIC IS THE SYSTEM IN OPERATION?

    As the tap commences, the application-dedicated software records a data log and produces a live graph for quality control. A stream-tracking mechanism ensures reliable operation in typical installation conditions. When slag appears and exceeds an operator-defined amount, an alarm is automatically triggered. The system is designed to ensure accurate, real-time detection of steel and slag independent of charge weight and without operator intervention.

  • Specifications +


    MWIR-640-SDS CAMERA UNIT
    Measurement Range: 500 to 1800 °C / 932 to 3272°F
    Pixel Resolution: 640 x 480 pixels
    Pixel Size / Pitch:
    		 17 μm
    Spectral Response:
    		 3.9 μm
    Max Frame Rate: HF: 60 Hz* / LF: 7.5 Hz
    Optic (HFOV x VFOV): 12° x 9° / 25° x 19°
    Focus Range:
    		 Min 0.75 m to infinity (motorised focus) - 12°
    Noise: 0.5 °C RMS (@500 °C 12°) 
    Dimensions: Approx. 450 mm/17.7 " x 373 mm/14,7 “ x 215 mm/8,5 “ (Full imager enclosure)
    Power Rating:
    		 12 to 24 V DC +/-10% 12 W / IEEE 802.3 at PoE+
    Weight: 10 kg / 22.05 lbs.
    Environmental Rating: IP66 / NEMA 4
    Compliance: EMC (EN 61326-1)
    SDS CAMERA SUPPLY
    Connection: Local connection interface between camera unit and image processing system
    Services: Water, instrument air, power input, located to the rear of the enclosure
    POWER SUPPLY UNIT (PSU)
    Components & Connections: Power supply, Ethernet communications (switch)
    Fibre optic data connection (option)
    PSU - Environmental Rating: NEMA Type 4
    Size:
    		 380 x 380 x 211 mm / 15 x 15 x 8.3 in.
    Weight:
    		 15kg / 33 lbs.
    IMAGE PROCESSING UNIT
    Slag/Steel Detection:
    		 Alarm activation when a pre-set percentage of either slag or steel/metal detected within defined window
    User Display:
    		 Front page information display and location identifier. External data displayed via interface input.
    Automatic Functions:
    		 Auto tap detection, stream tracking, steel/slag ratio, thermal video and video file recording, log file of all data including tap number, clear display of steel/slag percentage (bars, numbers and graphs), alarm colours, etc.)
    Software:
    		 IMAGEPro-SDS - Advanced Image Processing and Application Software
    Interfacing:
    		 Open Data Interface, Modbus TCP/IP, Moxa I/O unit
    * 60 Hz instruments are subject to different export restrictions in different authorities and countries around the world. All sales must be subject to export licence review.

  • Frequently Asked Questions +


    Question Answer 
    What is a slag detection system and what does it do? The LAND SDS (Slag Detection System) is a proven thermal imaging system that automatically detects the transition from steel to slag during tapping, enabling operators to terminate the tap at the optimal moment. Using a high-resolution 640 × 480 pixel MWIR thermal imaging camera with specialized 3.9 µm spectral filtering to see through smoke and fumes, the SDS delivers improved yields, higher-quality steel and reduced downstream processing costs—with typical slag depth reductions of up to 25% compared to traditional methods.
    How does the LAND SDS actually detect slag during tapping? As the tap runs, the SDS camera continuously images the pouring stream and the dedicated ImagePro-SDS software calculates the live ratio of steel to slag, plotting it on a real-time graph. Because slag and steel radiate differently at the 3.9 µm wavelength, the system distinguishes the two regardless of charge weight. A built-in stream-tracking function keeps the measurement locked on the stream even if it shifts. Once slag exceeds the operator-defined threshold, an automatic alarm fires—and the system can be wired to stop the tap directly.
    Can SDS see through the smoke and fume in a melt shop? Yes—that's a key design advantage. The SDS uses the MWIR-640-SDS camera operating at 3.9 µm wavelength, specifically chosen because it cuts through the smoke, dust, particles and hot gases present during tapping that would blind visible or LWIR cameras. Combined with the 640 × 480 pixel high-resolution detector and up to 60 fps frame rate, operators get a clear, usable thermal image of the tapping stream even in the harsh, dirty conditions typical of BOF and EAF melt shops.
    Does SDS work on both BOF and EAF, and on other metals? Yes—the SDS is designed for operators of secondary steelmaking vessels including Electric Arc Furnaces (EAF), Basic Oxygen Furnaces (BOF) and stainless steel operations. It's also proven in non-ferrous smelting for copper, platinum and other metals. The system measures steel/slag transition independent of charge weight and without operator intervention, adapting well across different vessel types and tapping routines. Hundreds of installations worldwide demonstrate its reliability across diverse operations.
    How much slag carryover can SDS realistically reduce? In practice, plants using SDS have documented slag depth reductions of up to 25% compared to traditional visual stream monitoring. This translates directly to: reduced downstream processing time and materials, improved steel quality and consistency, extended ladle refractory life through reduced slag attack, and improved plant throughput and operating margins. The consistent, automatic detection improves operator response time and removes human variability at end-of-tap—where most slag carryover occurs.
     How does SDS integrate with our plant systems and what data does it record?  SDS runs on LAND's Image Pro-SDS software and connects through open, industry-standard interfaces—Open Data Interface, Modbus TCP/IP, OPC UA and configurable I/O modules—integrating with existing automation and Level 2 systems. It outputs real-time slag/steel percentages, alarm status and sensor health at up to 60 fps. For every tap, the system automatically logs data files and archives thermal video for quality control. Remote viewing is available anywhere on the plant network.

  • Field of View (FOV) +


       Distance   4m   5m   7.5m   10m    15m 
     12° x 9°  Width:  0.8 m  1.1 m  1.6 m  2.1 m  3.2 m
     Height:  0.6 m  0.8 m  1.2 m  1.6 m  2.3 m
     IFOV:  1.3 mm   1.6 mm   2.5 mm  3.3 mm  4.9 mm
     25° x 19°  Width:  1.8 m  2.2 m  3.3 m  4.4 m  6.7 m
     Height:  1.3 m  1.7 m  2.5 m  3.3 m  5.0 m
     IFOV:  2.7 mm  3.4 mm  5.1 mm   6.8 mm   10.2 mm 

  • Documentation +

  • Related Applications +

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  • Software +

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