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Summary
OneSteels Whyalla Steelworks in South Australia is a fully integrated plant which operates a single blast furnace.
Following a number of years of in-house continuous development within Ironmaking, a comprehensive liquid
measurement system has been established which incorporates a novel iron on-torpedo weighing technique and
slag liquid measurement system. This system which includes torpedo tracking at key locations of the Whyalla
Steelworks has been in full plant operational use for over six years. Throughout this time it has been providing a
suite of reliable liquid measurement and management information to both the Ironmaking and Steelmaking
departments.
The system features provide the ability to accurately measure, in real-time, the amount of liquid iron and slag cast
at the blast furnace. The continuous state of liquid accumulation is understood by incorporating these direct
measurements with a number of models of liquids generated in the furnace. Aside from blast furnace liquid
accumulation information, casting rates of iron and slag, torpedo locations and batch-weights at the blast furnace
and basic oxygen steelmaking plant, other useful information is also available. This data includes the torpedo
empty-weight, dead-weight, the torpedo carrying-capacity (an important measure for tracking the refractory wear or
skulls in a torpedo vessel), as well as independent accurate tonnes of hot metal poured at Steelmaking and hot
metal dumping stations. The time since the torpedo was last filled is also provided; this relative age of stored iron
is a key input into the torpedo movement and steelmaking pacing program.
An automatic calibration routine of the on-torpedo weighing system exists, which uses as the standard reference
the hot metal weighbridge at Steelmaking.
This paper details the development history, the design concept and the operational implementation of this
integrated blast furnace liquid measurement and management system.
Key words
Blast furnace, BOS, liquid measurement, casting, liquid iron, slag, liquid accumulation.
Introduction
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Torpedo identification:
Each torpedo is equipped with an identification tag,
mounted on a pole, which is positioned to be directly
in front of a tag reader when in a filling or pouring
position.
Identification of the torpedoes is achieved with a RFID
tag reader system (radio-frequency identification).
Eight RFID tag readers are installed, one at each of
the four blast furnace filling positions, one at each of
the three BOS pouring positions, and one on the line
to the hot metal dump pits. These tag readers
communicate with the dedicated blast furnace PLC.
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The tag readers under the blast furnace cast floor are
connected via a DeviceNet network to the PLC. The
tag readers at the BOS site and dump pit line are
connected to a separate DeviceNet network, and the
signal transmitted back to the blast furnace weighing
system PLC.
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Torpedo Tracking:
A tracking display is used to monitor the location of all
the torpedoes at key locations on the plant with the
tonnes of iron in each. This display only shows
torpedoes in locations of filling and pouring positions,
if between these positions it is shown in the unknown
location column. GPS is not used at this stage to
show torpedoes in transit. A total available hot metal
tonnes in the system is shown and trended.
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Abbreviations
Acknowledgements
References
Conclusion
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