Case Study Slag Detection Celsa Steel UK

AMETEK Land has delivered its SDS-640 slag detection system to Celsa Steel UK to improve yield during the tapping process. 

Celsa Steel UK is the largest producer of steel reinforcement products in the UK, and one of the country’s largest manufacturers of high-quality steel long products including wire rods, reinforcing bars, high-yield coils, flat bars, channels, and angles. 

Producing approximately 1.2 million tonnes of finished product, Celsa was experiencing slag carryover on a frequent basis, resulting in a loss of steel. To reduce the loss of yield and improve accuracy in ladle slag measurement, the company installed AMETEK Land’s SDS-640 slag detection system

The SDS-640 slag detection system is a proven solution for accurate and timely detection of slag carry-over, allowing steel plants to improve product quality, reduce slag carry-over and improve operator safety.

Celsa Case Study

Specifically designed to survive and operate in challenging and hostile environments, it has a high-resolution thermal imaging camera that detects the transition between liquid metal and slag, using the 3.9μm wavelength to see through smoke, dust, and fumes.

Following installation of the system, Scott Evans, Process Manager at Celsa Steel UK, said: “The system is working as we expected, and is delivering quantifiable cost benefits. It has led to a reduction in ladle tips – decreasing delays – an increase of ferro alloy recovery, and better control of the hot heel.” 

Other benefits of the system include improved operator response times and consistency at the end of each tap. Compared with traditional methods of tapping stream monitoring, slag depths of up to 25% are being achieved, as well as improved productivity and efficiency.

 Temperature Range: 800 to 1800 °C / 1472 to 3272°F  
 Spectral Response: 3.9 μm
 Pixel Resolution: 640 x 480 pixels
 Frame Rate: 50 Hz
 Optics (FOV): 12° x 9°, 43° x 33°
 Interfacing: Gbit-Ethernet
 I/O Options: I/O-modules and digital interfacing via IMAGEPro

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.

SDS uses a high-resolution thermal imaging camera to detect the transition between steel and slag. The dedicated thermal imaging camera has been specifically designed to survive in the harsh operating conditions and utilizes a particular wavelength to reduce obscuration caused by smoke and fume. Data is presented to the operator in real time enabling them to make informed decisions about the tapping process and the system provides clear alarm notifications.