Slag Detection System

AMETEK Land Slag Detection System (SDS)

The AMETEK Land Slag Detection System (SDS) enhances steelmaking efficiency by improving tap control, increasing steel yield, and minimizing costly downstream operations. It provides accurate real-time slag detection, enabling faster and more reliable operator decisions. During the tapping process, the interface between molten steel and slag changes rapidly. The SDS continuously monitors this transition using a high-resolution thermal imaging camera specifically engineered to withstand harsh steel plant environments. Advanced thermal imaging technology minimizes the effects of smoke, dust, and fume interference, ensuring dependable performance. Clear visual monitoring and instant alarm notifications help operators stop tapping at the optimal time, reducing slag carry-over into the ladle. The system is also suitable for monitoring secondary steelmaking vessels such as EAFs, BOFs, and stainless-steel production. Customized versions are available for copper, platinum, and other metallurgical applications. With a wider field of view, the SDS can additionally monitor ladle freeboard when required.

ENHANCED STEEL QUALITY

The SDS delivers consistent and repeatable tapping performance, helping operators reduce slag contamination while improving process stability. By minimizing slag carry-over, the system supports higher steel quality and more efficient production.

LOWER OPERATING COSTS

Reducing slag entering the ladle decreases the need for additional downstream processing, saving both time and operational resources. This results in improved plant productivity, lower maintenance requirements, and increased overall profitability.

INTELLIGENT AUTOMATION

The SDS software continuously analyzes the tapping process using advanced image processing and stream identification algorithms. Live trend graphs and automated alarm functions provide reliable slag detection without relying on operator judgment. The system ensures consistent performance regardless of varying tap conditions or charge weight, enabling safer and more efficient steelmaking operations.

KEY FEATURES AND BENEFITS

Higher Production Yield

Fully Automated Operation

Improved Steel Quality

Accurate Slag Detection

Lower Maintenance & Energy Costs

Instant Operator Alerts & Open Data Connectivity

ADVANCED SLAG DETECTION

The AMETEK Land SDS delivers real-time slag detection to minimize slag carry-over and improve steel transfer efficiency. Designed for plug-and-play installation, the system integrates seamlessly into existing steel plants with minimal setup while continuously recording process data for monitoring and analysis.

REAL-TIME PROCESS VISUALIZATION

Monitor live thermal images, slag percentage, stream width, tap duration, alarm status, and sensor health from an intuitive operator interface. Essential process information is displayed clearly to support faster and more accurate tapping decisions.

REMOTE PLANT MONITORING

Access live and recorded tap data from any network-connected workstation. Video, process trends, and event logs are automatically stored for quality analysis and process optimization. Open Data Interface (Modbus TCP & I/O) enables seamless integration with plant automation systems.

SEAMLESS PLANT CONNECTIVITY

High-speed fibre-optic Ethernet communication ensures reliable data exchange between the SDS and plant control systems. Process data—including tap number, heat number, steel grade, slag percentage, and sensor status—is securely recorded for traceability and reporting.

INTELLIGENT STREAM TRACKING

Advanced image-processing algorithms automatically track the molten steel stream, accurately identifying its position and width throughout the tap. The system compensates for changing stream movement while minimizing interference from background heat, ensuring consistent and reliable slag detection.

IMAGEPro – SDS application software

LIVE PROCESS MONITORING

View real-time thermal images with live steel, slag, and alarm status. Process data is continuously updated and can be shared with plant control systems via the Open Data Interface.

AUTOMATIC STREAM TRACKING

Advanced image-processing technology automatically identifies and tracks the molten steel stream, minimizing the impact of background heat and ensuring accurate slag detection.

LIVE ANALYTICS & ALARMS

Interactive bar and trend graphs display steel and slag percentages throughout the tap. Visual alarm indicators notify operators instantly, while thermal video, graphs, and process data are automatically recorded for analysis and quality control.

HOW SLAG CARRYOVER IS PREVENTED

The following sequence of screens clearly illustrates how the SDS tracks the onset of slag, finally activating an alarm to stop the tapping process, preventing slag carry-over.

The alarm is still showing green. Actual steel level is 88.6%, slag level at 11.4% (overall steel level 99.5%, overall slag level 0.5%).