FROM FURNACE TO CASTER -...

STEELMeasurement Solutions for Process Optimisation

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AGELLIS – TAKE CONTROL OF YOUR PROCESSAgellis Group develops, manufactures and markets measurement solutions, facilitating process optimisation for the global molten metals industry. We have a strong commitment to enhance our customer’s productivity, safety and long-term profitability.

OUR SOLUTIONS ENABLE increased automation, improved process efficiency and enhanced safety for personnel within metal production. Our solutions are based on two platforms, EMLI (Electromagnetic Level Indication) and VISIR (Vision and Infrared), developed from our unique expertise in both electromag-netic and vision technologies, extensive knowledge of industrial processes and close customer cooperation.

More than 30 years’ experience of global metal industry along with continuous investment in research and develop ment has enabled us to achieve a world- leading position in molten metal level measurement, detection and monitoring.

A “state of the art” electromagnetic platform for molten metal measurement systems.

A vision and thermographic camera platform for critical process monitoring.

VISIR

CONTENTSFrom furnace to caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EMLI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

EMLI-MetalSlag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

EMLI-EAF Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

EMLI-FurnaceSlag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

EMLI-LadleSlag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

EMLI-TundishLevel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

EMLI-MouldLevel Suspended .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

EMLI-MouldLevel Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

VISIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

VISIR-LadleDeslag.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

VISIR-MetalDetect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

VISIR-LadleSafe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

VISIR-FurnaceSafe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

VISIR-TorpedoSafe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Agellis’ solutions assist metal producers in stabilising their process, reducing production costs while improving safety from furnace to caster. Whether you need to control slag carryover, precisely

measure steel levels or avoid costly breakouts, Agellis has the optimal solution for your process.

FROM FURNACE TO CASTER

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FROM FURNACETO CASTER

1 EMLI-MetalSlag

The system monitors slag taphole or slag runner to detect metal entering the slag stream.

See page 7.

2 VISIR-TorpedoSafe

Infrared monitoring of your torpedos minimises the risk of liquid iron breakout and maximises your torpedo refractory lifetime.

See page 19.

3 VISIR-LadleDeslag

Vision monitoring and evaluation of your deslag-ging process helps you get in control of your ope-rations and homogenise the skimming practices.

See page 15.

5 EMLI-FurnaceSlag

The system monitors steel tapping to detect slag in the stream and control slag carryover.

See page 9.

6 VISIR-LadleSafe

Infrared monitoring of your steel ladles minimises the risk of liquid steel break-out and maximises your ladle refractory lifetime.

See page 17.

7 VISIR-FurnaceSafe

Infrared monitoring of your furnace shell minimises the risk of liquid steel break-out and maximises your operational furnace availa-bility while at the same time increasing safety.

See page 18.

8 EMLI-EAF Level

This tracking system is a unit for recording and tracking steel levels in the furnace without losing time for extra measurement.

See page 8.

9 EMLI-LadleSlag

The system continuously monitors the tapping stream from ladle to tundish to minimise slag carryover and maximise steel transfer yield.

See page 10.

12 EMLI-MouldLevel Suspended

The system measures precise steel levels using a suspended sensor in a continuous casting mould.

See page 12.

10 EMLI-TundishLevel

The system monitors true steel levels in tundishes al-lowing process benefits such as increasing inclusion float out, improving production speed, minimising skulls and avoiding slag in the mould.

See page 11.

4 VISIR-MetalDetect

The system improves your metal yield through detection and control of metal losses in the deslagging process.

See page 16.

11 EMLI-MouldLevel Edge

The system measures precise steel levels using sensors mounted directly on the moulds during continuous casting.

See page 13.

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6Agellis Group develops and manufactures measurement solutions for Iron and Steel industries worldwide.

Agellis solutions help metal producers to stabilise their process, improve safety and lower their environmental impact.

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ELECTROMAGNETIC LEVEL INDICATION


EMLI-MetalSlagEMLI-EAF LevelEMLI-FurnaceSlagEMLI-LadleSlagEMLI-TundishLevelEMLI-MouldLevel SuspendedEMLI-MouldLevel Edge

Avoid dangerous situations by monitoring the slag stream for the presence of iron.

Agellis EMLI-MetalSlag sensors

THE EMLI-METALSLAG SYSTEM continuously monitors slag flow during furnace tapping and provides early alarm outputs when metal is detected in the slag stream. These outputs can be used to immediately end slag tapping by giving visual and audible alarms.

The EMLI-MetalSlag system is typically used on Iron making blast furnaces to avoid iron reaching the water granulation process.

METAL DETECTION DURING SLAG TAPPING

EMLI-MetalSlag

http://agellis.com/solutions-and-products/ solutions-and-products-sub/iron-making-solutions/

emli-metalslag/

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• Detect iron in slag runner/tap hole. • Avoid dangerous situations in following processes. • Simple installation and low maintenance.

USER BENEFITS & ADVANTAGES

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• Control consistent slag carryover with a fast response time.• Calculation of slag transfer amount.• Detect vortex formation during tapping.• Flames and smoke does not affect the system.• Fast response to slag carryover, ensures a minimum of slag

in ladle.• Ensure consistent secondary metallurgy process.


THE EMLI-FURNACESLAG SYSTEM continuously monitors the steel flow during furnace tapping and provides alarm outputs when slag is detected. These outputs can be used to immediately end tapping, while giving visual and audible alarms.

The system also gives operators control over vortex formations during tapping. The electromagnetic design ensures that the system is not affected by smoke and flames. The robust EMLI sensors and cabling are customised to fit any fur-nace and tap-hole arrangement with only minimal modification to existing equip-ment.

A consistent secondary metallurgy process is achieved using EMLI-Furnace Slag.

ELECTROMAGNETIC SLAG DETECTION FOR FURNACE

EMLI-FurnaceSlag

AgellisEMLI Sensors

http://agellis.com/solutions-and-products/solutions-and-products-sub/steel-making-

solutions/emli-furnaceslag/

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Avoid slag transfer by a precise slag detec-tion which is not affected by flames or fumes.

• Measure steel level accurately, when taking temp/O/sampling.• No time loss for an additional measurement. No additional

comsumables.• Optimise side wall injection efficiency, by knowing and

managing the steel level.• Provide tracking of the steel level trend assisting hot-heel

management.


The Agellis sensor is mounted on the mani-pulator itself and provides a steel level everytime a sample is taken.

THE AGELLIS EMLI-EAF LEVEL SYSTEM permits level measurements to be per-formed simultaneously with temperature and material sampling, without any time loss or extra consumables.

The system is easy to use with a sensor mounted in the existing probe holder on the manipulator.

During the immersion sequence an electromagnetic sensor picks up conductivity changes as it passes through different materials. It locates the exact position of the molten metal level and feeds it to the plant PLC.

The Agellis measurement system can be used in all EAF furnace types where molten metal access is possible and is custom built to fit most common slag door manipulators.

EMLI- EAF Level

ELECTROMAGNETIC STEEL LEVEL TRACKING IN EAF

EMLI-EAF Level

http://agellis.com/solutions-and-products/ solutions-and-products-sub/steel-making-

solutions/emli-eaf-level/

MORE INFORMATION

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Agellis EMLI-TundishLevelTundish mounted sensors

THE EMLI-TUNDISHLEVEL SYSTEM continuously monitors the true steel levels in the tundish and provides outputs to control the flow from the ladle to main-tain desired operating levels without being affected by the presence of slag or protection powder. This allows a precise steel level control ensuring a constant pressure head, minimised intermix areas and accurate draining procedures.

Typical benefits are more constant casting speeds, avoiding slag in the moulds, higher production output and substantial yield increase due to proper and con-sistent draining control.

CONTINOUS TUNDISH STEEL LEVEL MEASUREMENT

EMLI-TundishLevel

• Continuous true steel level measurement.• Enable reduction in manpower.• Optimise yield at every drain. Avoid slag in mould & breakouts.• Minimised intermixed area.• Allow consistent ferrostatic pressure in tundish.


http://agellis.com/solutions-and-products/ solutions-and-products-sub/continuous-casting/

emli-tundishlevel/

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The tundish is connected at the caster to precisely monitor the steel levels without being affected by slag amounts or powder.

THE EMLI-LADLESLAG SYSTEM continuously monitors steel flow during ladle teeming when casting and provides alarm outputs when slag is detected. These outputs can be used to immediately end teeming.

The use of a well-functioning slag detection system increases yield signifi cant ly due to consistent and objective gate closure, every time. The EMLI sensors and cabling are customised to fit any ladle and sliding- gate arrangement with only minimal modification to existing equipment. To ensure high functionality, the sen-sors are engineered to be used in high temperatures allowing use in Vacuum Degassing process routes.

Agellis EMLI Sensors

ELECTROMAGNETIC SLAG DETECTION FOR LADLES

EMLI-LadleSlag

• Control consistent slag carryover with a fast response time.• Increase yield by leaving minimal amounts of steel in the ladle.• Close to 100 % availability.• Long life high temp sensors, engineered for VD process routes. • Can handle any steel grades. No additional calibration necessary.


http://agellis.com/solutions-and-products/ solutions-and-products-sub/continuous-

casting/emli-ladleslag/

MORE INFORMATION

The ladle is connected at the tower and the tapping stream is monitored to detect the presence of slag.

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The sensor is placed in the mould either by an automatic manipulator or a manual arm.

Agellis EMLI-sensors

THE EMLI-MOULDLEVEL SUSPENDED SYSTEM constantly monitors steel level in the mould during casting and provides outputs to control the flow to maintain desired operating levels.

To position the sensor in the mould, an automatic manipulator or a manual arm can be used.

The electromagnetic technology ensures that true steel meniscus levels are measured irrespectively of the amount of mould powder.

The system is 100 % compatible with the use of EMS, EMBr and coated moulds.

ELECTROMAGNETIC MOULD LEVEL MEASUREMENT

EMLI-MouldLevel Suspended

• Electromagnetic technology, measures true steel meniscus level independently of powder thickness.

• Fast true response time.• Automatic and fast calibration.• Can be used with EMS, EMBr and coating conditions.



emli-mouldlevel-suspended/

MORE INFORMATION

The sensors are mounted on the mould itself and are out of the way, allowing operator to work freely.Agellis EMLI-MouldLevel

Edge Sensor

THE AGELLIS EMLI-MOULDLEVEL EDGE UNIT constantly monitors steel level in the mould during casting and provides outputs to control the flow to maintain desired operating levels.

The electromagnetic technology ensures that true steel meniscus levels are measured irrespectively of the amount of mould powder.

The system is typically designed for use in slab moulds and large blooms. Edge mounted sensors ensure minimum inference with casting operations.

ELECTROMAGNETIC MOULD LEVEL MEASUREMENT

EMLI-MouldLevel Edge

http://agellis.com/solutions-and-products/solutions-and-products-sub/continuous-casting/

emli-mouldlevel-edge/

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• Electromagnetic technology, measures true steel meniscus level independently of powder thickness.

• Fast true response time.• Automatic and fast calibration.


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VISION AND INFRARED

VISION ANDINFRARED

VISIR-LadleDeslagVISIR-MetalDetectVISIR-LadleSafeVISIR-FurnaceSafeVISIR-TorpedoSafe

The system allows a clear view of the skim-ming operations and an objective rating of the results.

THE VISIR-LADLEDESLAG SYSTEM is designed to monitor ladle deslagging op-erations in order to quantify the percentage of slag covered area. Thus, skim-ming operators using the VISIR-LadleDeslag system can produce slag free ladles consistently.

The system monitors the deslagging operations in real time. Using the VISIR-LadleDeslag system, helps control sulphur amounts and re-oxidation during ladle treatment.

By limiting process variations and ensuring that the deslagging process is more consistent the variations in quality in the final product are minimised.

The VISIR-LadleDeslag system automatically track and store vital information for each heat and makes sure your quality assurance program is met.

LADLE SKIMMING MONITORING

VISIR-LadleDeslag

• Consistent and objective monitoring of deslagging process.• Historical data stored in open and searchable database. • Metal loss warning. • Yield increase.


http://agellis.com/solutions-and-products/ solutions-and-products-sub/steel-making-solutions/

visir-ladledeslag/

MORE INFORMATION

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VISION AND INFRARED

VISION ANDINFRARED

Avoid metal losses during deslagging operations.

THE VISIR-METALDETECT SYSTEM is designed to monitor the ladle or furnace deslagging operations in real time to detect when metal is also being poured within the slag stream. Thus, a minimal amount of metal is lost and yield improved.

VISIR-MetalDetect system enables you to assist operators to control their metal losses in a safe and secure manner. By monitoring the deslagging stream and informing the operator when metal is detected the process can be modified quickly and safely.

By controlling the deslagging process variations and ensuring that the metal loss-es are significantly reduced, yield improvements and quality consistency can be achieved.

METAL DETECTION DURING DESLAGGING

VISIR-MetalDetect

• Consistent and objective monitoring of losses during skimming.• Historical data stored in open and searchable database. • Help operator avoid losses, resulting in yield increase. • Increase lifetime of your slag pots.



visir-metaldetect/

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Detect dangerous ladles before a breakout occurs. Make sure only safe ladles are taken to the caster.

THE RISK OF A LADLE BREAKOUT will always be present in steelmaking with equipment damage, personnel injuries and loss of production as a consequence.

Eliminate dangerous and costly situations by scanning and evaluating the con-dition of each ladle in your fleet before sending it to the caster.

Using the historical database, refractory performances can be objectively eval-uated and average ladle refractory lifetime can be increased in a safe way.

LADLE HOT SPOT DETECTION SYSTEM

VISIR-LadleSafe


visir-ladlesafe/

MORE INFORMATION

• Hot spot detection and warning. • Maximise ladle refractory lifetime.• Integrated with plant PLC and network.• Maximising safety in ladle handling areas.• Historical database open to process metallurgist.


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VISION AND INFRARED

VISION ANDINFRARED

Continuously check the furnace shell for signs of weakness and detect potential breakouts before they happen.

THE RISK OF BREAKOUTS will always be present in steelmaking with equip ment damage, personnel injuries and loss of production as a consequence.

VISIR-FurnaceSafe system continuously monitors the furnace shell thermal sta-tus and trends temperatures for over 100 000 measuring points.

The monitoring system automatically alerts you when detecting early signs of dan-gerous hot spots, helping you to handle the situation before it becomes a hazard.

VISIR-FurnaceSafe stores data in a measurement database, letting you create weekly reports and evaluate refractory performance.

FURNACE BREAKOUT PREVENTION

VISIR-FurnaceSafe


visir-furnacesafe/

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• Hot spot detection and warning. • Used with LF, RH, EAF, AOD, LD/BOF.• Maximising safety in furnace areas.• Capability of handling up to five cameras.• Historical database open to process metallurgist.


Check each torpedo for hot spots, detect potential problem areas and evaluate refractories conditions over time.

THE RISK OF BREAKOUTS will always be present in steelmaking with equipment damage, personnel injuries and loss of production as a consequence.

Eliminate dangerous and costly situations by scanning and evaluating the condi-tion of each torpedo.

Using the historical database, refractory performances can be objectively evalu-ated and average refractory lifetime can be increased in a safe way.

TORPEDO HOT SPOT DETECTION

VISIR-TorpedoSafe

• Hot spot detection and warning. • Maximising refractory lifetime. • Maximising safety in torpedo handling areas.• Historical data stored in open and searchable database.


http://agellis.com/solutions-and-products/ solutions-and-products-sub/iron-making-solutions/

visir-torpedosafe/

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Agellis Group AB Tellusgatan 15, 224 57 Lund, Sweden +46 46 10 13 60, [email protected] www.agellis.com

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