Are you constantly concerned about the potential risks of metal breakouts?
Are you feeling that your ladle refractories sometimes could last a few more heats, but you must think of safety first?
Would you feel more confident in pushing the ladle refractory lifetime if a system scanned every ladle before it was sent to the casting bay?
If the answer to any of the above is YES, LadleSafe is what you are looking for. LadleSafe is based on infrared camera technology using data analysis to evaluate the steel structure thermal status of your ladles.
How does it work?
The crane operator positions the ladle in the measurement position which is usually located at the end of the liquid metal processing stage, just prior to reaching the casting bay. He ensures that all sides of the ladle are inside the field of view of the thermal cameras.
Once the ladle is in position, the crane operator starts the measurement by the use of a touch screen monitor. The system reads the ladle I.D, performs a few checks, and then starts taking thermal data used for the analysis. Typically the analysis result of the thermal status is returned to the crane operator within seconds. The result is summarised in a recommendation which assists the crane operator in tracking down dangerous ladles. Based on the analysis results the operator decides if the ladle is safe to continue using.
The operator is also given the opportunity to study some parts of the ladle analysis in detail, as well as study a graphical display of the previous measurement results of the same ladle.
Breakout Early Warning – Early warning of potentially dangerous ladle hot spots. LadleSafe detects hot spots long before they are visible to the naked eye (red hot), thus allowing preventive actions to be taken long before a critical situation occurs.
Temperature Trending – A LadleSafe measurement of the ladle steel structure temperature distribution also presents the temperature evolution over time. This information is useful for the refractory maintenance personnel.
Optimal Refractory Lifetime – LadleSafe allows ladle refractory lifetime to be maximised. A direct measurement of the ladle steel structure temperature when in use is likely to reflect the refractory status. Thus, as long as the temperature stays below a predefined value, the refractory should be safe to continue using.
Data Mining – LadleSafe contains a measurement results database to be used for evaluation purposes. This opens the way for a more precise ladle fleet management which avoids excessive thermal loads on some individual ladles and prolongs ladle refractory lifetime. Database mining is also useful in tracking down production actions detrimental to the ladle refractory.