The steel industry has always embraced innovation. But many critical processes still rely on physical inspections and scheduled maintenance strategies that increase the likelihood of catastrophic equipment failure.
Ladle monitoring and Electric Arc Furnace (EAF) monitoring applications, for example, require highly skilled technicians to access the site, assess wear, and evaluate the condition of equipment.
Instead, steel manufacturers need a new solution that allows Operators to see real-time thermal and visual data from a safe, centralized location. Continuous Thermal Monitoring solutions leverage advanced thermal and visual cameras to provide steel plants with 24/7 coverage of ladles, electric arc furnaces, and other critical equipment.
With greater visibility into the actual condition of assets, steel plants can reduce the risk of breakouts, optimize maintenance schedules, and improve workplace safety.
To learn more about the benefits of Continuous Thermal Monitoring solutions, download our recent white paper: Mitigating Risk in the Steel Industry – The Benefits of Continuous Thermal Monitoring
1. Mitigating the Risk of Ladle Breakouts
Ladles are critical for transporting and refining molten steel. However, they also present several maintenance challenges that must be addressed to ensure their safe and reliable operation. Breakouts are among the most dangerous and costly failures that can occur in steel manufacturing, and they can lead to injury or death if workers are exposed to molten materials.
Continuous Thermal Monitoring solutions reduce the risk of breakouts by providing real-time thermal data to the Operations & Maintenance teams. Mounted thermal cameras measure external ladle temperature profiles to detect uneven heating or hotspots that may indicate refractory degradation. Instead of waiting for an inspection, Operators can immediately stop production and initiate a repair.
2. Optimizing Relining Intervals
Determining optimal relining frequency is a complex and inexact science that varies based on a number of factors. Relining too often increases costs and leads to unnecessary downtime, while delays can lead to degradation of the refractory lining and breakouts.
Continuous Thermal Monitoring provides real-time data on refractory wear, hot spots, and operational efficiency. Instead of relying on rough estimates, steel plants can optimize relining schedules based on the actual condition of the refractory lining. This allows for partial repairs to localized, high-wear areas instead of unnecessary full relines. Not only does this extend the life of the ladle, but it also allows steel plants to schedule relining during convenient windows to reduce downtime.
3. Preventing EAF Steam Explosions
EAFs have changed the way steel is produced, offering greater flexibility, energy efficiency, and sustainability compared to traditional blast furnaces. However, they also create unique risks and operational challenges that require specialized expertise.
Water-cooled panels prevent the furnace shell and roof from overheating, while other cooling systems protect critical components such as the transformer, hydraulic actuators, and electrodes. Even small leaks can trigger a steam explosion that results in injuries, production shutdowns, and costly repairs.
Thermal sensors monitor the EAF shell, roof, panel, and electrode temperatures to provide early warning of water leaks from the cooling system. The sensors automatically detect a sudden or localized temperature drop that could indicate a leak, initiating an emergency shutdown to prevent water from reaching the molten steel.
4. Detecting Furnace Wall Failure
The refractory lining of the EAF wall is repeatedly exposed to extreme temperatures. Each heat cycle expands and contracts the lining, weakening its structure and leading to localized failures. Similarly, molten slag can react with the lining and break down protective materials.
Thermal sensors continuously track furnace wall temperatures to detect hot spots and signs of localized wear. Operators can use this data to identify thin refractory zones before they lead to collapse, shut down the EAF, and conduct partial repairs to the affected panels.
The Benefits of Continuous Thermal Monitoring
Continuous Thermal Monitoring solutions equip Operators with real-time temperature data, enabling them to proactively identify faults and take corrective action before catastrophic failure occurs.
Many steel manufacturers start by deploying cameras to monitor a specific asset or production process. This pilot project helps their personnel become familiar with the features and capabilities of the solution before expanding into additional facilities or applications.
The sensors have been designed and built to withstand the challenging environments typical for applications such as ladle monitoring and Electric Arc Furnace monitoring.
Rather than rely on time-based physical inspections or reactive maintenance strategies, steel plants can take a proactive approach that improves asset utilization, enhances workplace safety, and mitigates the risk of catastrophic equipment failure.
To see how you can deploy Continuous Thermal Monitoring solutions in your facilities, download our latest white paper: Mitigating Risk in the Steel Industry – The Benefits of Continuous Thermal Monitoring