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Hot Metal Ladle Intelligent Digital Imaging Online Safety Mo

2020-06-08 17:42

Overview

Molten iron ladle in metallurgical iron works is an equipment used to hold and receive molten iron and transport it. The outer shell of molten iron ladle is generally made of welded boiler steel plates with the thickness of the cladding wall and bottom steel plates between 14-30mm and 24-40mm respectively. Molten iron inner lining is generally composed of insulation layer, permanent layer and working layer. The insulation layer is close to the shell steel plate, about 10-15mm thick, the main role is to reduce heat loss, commonly used asbestos board masonry; The permanent layer is about 30-60mm thick, which is mainly used to prevent molten iron from burning through. It is usually built by clay bricks or high aluminum bricks with certain thermal insulation properties. The working layer is in direct contact with molten steel and slag, which is vulnerable to chemical erosion, mechanical erosion, quench and heat and spalling. The liner of molten iron ladle is in contact with the slag of high temperature for a long time, which is eroded by the main stream and slag, especially the ladle used for refining outside the furnace. Liner erosion not only reduces the life of molten iron, but also increases the content of inclusions in molten iron. We know that the refractory lining life of molten iron works is limited, and its service life may be shortened by the damage of refractory brick caused by mechanical vibration. As the refractory lining wears away or cracks appear, the outer material of the molten metal will be exposed. If not found in time, can lead to molten metal bag collapse or leakage, threatening the safety of employees, damage to equipment.

 

Project Background

The lining of molten iron bag will be cracked, bulked and dropped due to chemical erosion, mechanical vibration and rapid cooling, etc., when the local damage of refractory material is serious, but not found, it will cause serious leakage accident. In the case that the molten iron ladle has defects in the early stage until complete failure, it will gradually develop from point to surface. In the case that the lining of the ladle has spalling in the early stage, the temperature in the spalling point area will be abnormally high, and the temperature in the defect area will be significantly higher than that in other positions. Fortunately, the patented Hot Metal Ladle Safety Monitoring and Warning System based on intelligent thermal imaging technology can detect the hot spots on the hot metal ladle, and can send out fault alarm earlier than the visual detection work.

Thus the timely termination of the work, and in the appropriate time at the best cost for the replacement work. The intelligent on-line monitoring terminal equipment will be placed in a solid shell and installed in a fixed position. When the molten iron ladle passes on the railway, the thermal imaging instrument can clearly capture the thermal image of the molten iron ladle full of contents. Professional building of hot metal ladle leakage on-line automatic monitoring system platform, to the temperature of the hot metal ladle real-time omni-directional change detection, can occur in the lining of crack defect in the detection and positioning, beat the previous state, and issue a report to the staff, preventive maintenance and realize the early warning in advance can wear the hot metal ladle leakage completely hidden trouble elimination in the bud. Reduce the risk of iron spill, eliminate the potential metal leakage hidden danger; This system can grasp the temperature distribution of each surface of molten iron ladle in real time, and find and locate the suspicious area of molten iron ladle under the prompt of the system, and take treatment measures in time. When transport vehicles passing from the monitoring area of hot metal ladle, monitoring system to trigger the record shot total radiation streaming video will be stored in a computer, by date automatically classified storage, also can view real-time images of the arbitrary point temperature, the hot metal ladle transport work condition does not need to stop operation to capture images, can be normal production process, when the monitor area appears higher than the set temperature will trigger the alarm, to remind staff, to avoid missing package accidents.

 

Project Characteristics

1) 365 days *24 hours of uninterrupted monitoring throughout the year: The client will display full-radiation infrared thermal video in real time, and users can check and analyze the temperature of the suspected defect points and areas in real time according to their needs, and automatically capture the highest temperature points;

2) Once the hot iron ladle is detected to enter the detection range, the host starts to record the hot iron video and saves it according to the date, which is convenient for viewing at any time in the later period. The recording stops when the hot iron packet leaves the detection range, greatly saving the memory storage space of the computer.

3) Automatic alarm: Three-level temperature alarm threshold can be set, which will be automatically analyzed by the system and sent to the alarm by sound and light alarm. Alarm points and temperature will be displayed on the thermography screen.

4) Authority management: Authorize different staff according to customer requirements;

5) Fault self-diagnosis: When the thermal imager fails, the system can remind the personnel on duty;

6) Restart and self-recovery: the system can automatically resume operation after power loss or network interruption;

7) Automatic classified storage: monitoring data, abnormal data and alarm information will be automatically stored in the corresponding device data column, enabling fast and accurate call analysis.

8) Automatic cruise: Automatic preset position cruise monitoring to reduce manual intervention;

9) Reports: Various reports can be customized according to customers' requirements. Reports can be generated by selecting values according to the time interval and exported in Word/Excel format.