Sahaviriya Steel Industries UK

Skimming Vision System Project

JOHN DUNNECHATCHAWAT SAE-JUNGPANYA PHADUNGSANTCHAROENCHAI SRISA-NGA NARIT PHONRAKKHET

Content

1. Introduction2. What is Skimming Vision System3. Trial test skimming Vision System4. Estimate Budget5. Time Line

1.Introduction

Current operation Currently no repeatable standardization on shifts Operator undertakes a visual estimation of slag remaining linked to the aim sulphur. An observation for an aim sulphur of 0.004% the operator skims a minimum of 90% . No recording of individual skimming performance. Longer than required treatment times

Aim & Benefits

Yield improvement Standardization Cost saving Spin off safety benefits Pre and post photo giving evidence on the skim to be compared to the sulphur

specification through the process. The operators are mimicking the learning from station 2 onto station1. Time wasted in over skimming.

2.What is Skimming Vision System? Architecture and Network Diagram ( Figure1).

Figure 1

2.What is Skimming Vision System?The Skimming Vision system for hot metal slag skimming uses a high definition thermal camera to take emission intensity signals from defined region of interest on the image ladle surface ( Figure2)

Figure2

2.What is Skimming Vision System?The Screen visually shows the outline of slag and hot metal in ladle during skimming process. It indicates slag coverage in percent and aim hot metal in percent ( Figure3)

Figure 3

Ownership

3.What is Skimming Vision System?While skimming , the slag coverage decreases. If the coverage reaches the aim target, a sign signal on the screen ( Figure4 ). At this point, the operator stops skimming manually

Figure 4

Skimming weight loss issue The result show that after skimming with thermal camera setting 70%

skim off can reduce the iron skimming loss approximately 1.17 t when compare with history data

3. Trial test skimming Vision System

Current skim loss compared to pre- camera

22772280

22842288

22922295

22992302

23052309

23112316

23202324

23282332

23352339

23422348

23522356

23602364

23710

2

4

6

8

10

12

Iron loss per ladleTotal skim loss Average skim lossLinear (Average skim loss)

Extended Trial

22772280

22842288

22922295

22992302

23052309

23112316

23202324

23282332

23352339

23422348

23522356

23602364

23710

2

4

6

8

10

12

Iron loss per ladle

Iron loss per ladle

Performance During Trial

$145.92

$138.04 $138.37

$147.96

$140.71$142.56

Aver. cost saving/heat ($) by Shift

A Shift B Shift C Shift D Shift E Shift All Shift

Benefits Reduce iron loss More accuracy slag skimming Ladle temperature analysis can apply in the future Increased iron units charged to the vessel and reduce the quantity of desulph slag going to HARSCO

The benefit below can changeable depend on cost of HM and the number of iron loss we saved.

3.In summary, Trial test skimming Vision System

Assumption save actual iron loss after install camera

heat produce/day save iron(t) accum saving/day (t) year saving(t) cost saving/y ($)

35 1.2560 43.96 15,605.9 $1,779,078.06

Saving per shift

8 Day Periods :

27/01/2015 - 03/02/2015

2. Accumulate Skimming Vision System of Desulphur Station2 Report

A Shift B Shift C Shift D Shift E Shift All Shift

Heat Produce Recorded 31 27 9 28 30 125

Aver. Iron loss/heat (t) 0.765 0.698 0.800 0.752 0.815 0.745

Aver. cost saving/heat ($) $128.13 $141.92 $176.07 $182.65 $128.20 $141.45

Iron Loss Saving (t) 38.489 35.134 10.811 34.585 35.438 154.456

Cost Saving ($) $4,387.72 $4,005.25 $1,232.48 $3,942.69 $4,039.88 $17,608.013

Saving

History data

Heats skim loss (t) Iron loss (t)50% avg iron loss/ladle (t)

120 800.5 400.25 3.34

Commissioning

126 313 156.5 1.24

Saving iron loss 2.10

$22,432.37

History data

Heats skim loss (t) Iron loss (t) 30% avg iron loss/ladle (t)

120 800.5 240.15 2.00

Commissioning

126 313 93.9 0.75

Saving iron loss 1.256

Cost Saving $18,041.36

4.Estimate Budgetary & Time Schedule

Time Schedule: Mar’15

Work to Progress

System to pick up the quality from the heat number and skimming aim.Look at adapting the CBM to reflect the reduced skimming loss.Construct a professional skimming station control panel to store the computer and monitor.Trial the gull wing skimming heads Install an ultrasonic level sensor in the Coag bulk silo.Audit the system.