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SDS - 炉渣检测系统

AMETEK Land Fixed Thermal Imagers and Line Scanners - SDS-E - Slag Detection

AMETEK Land 的炉渣检测系统(SDS)可提高产量,改善钢材质量并减少昂贵的下游加工成本。 钢包耐火材料的低磨损还带来了其他好处。

  • 概述 +


    在出钢结束时,渣和钢的含量相差很大。警报触发后,必须迅速终止出钢,以防止钢包中的炉渣过多。SDS 使用高分辨率的热成像摄像机来检测钢和炉渣之间的过渡。专用热成像摄像机是专门为在恶劣条件下工作而设计的,它利用特定的波长来减少烟雾和烟尘造成的遮挡。数据被实时呈现给操作员,使他们能够对出钢过程做出明智的决定,并且系统还会提供清晰的报警通知。

    适用于各种应用
    SDS 适用于包括不锈钢在内的二次炼钢容器(如 EAF、BOF)操作,也可用于铜和铂等其他冶炼操作。如果需要,系统还可用于指示安全高度,提供广阔的视野。

    提高产品质量
    经证明,使用 SDS 可以在每次出钢结束时改善操作员的响应时间和一致性。与传统的流监测方法相比,它可将炉渣深度减少多达 25%。

    降低下游加工成本
    额外的下游加工时间和材料成本加重了运营工厂的负担。通过控制炉渣残留,可以减少或消除这种昂贵的下游加工成本,从而提高工厂的产量、产品质量和经营利润。

    自动操作
    出钢开始时,应用专用软件会记录数据日志,并生成一个实时图表,用于质量控制。有一个流跟踪装置,用于确保在典型工作条件下可靠运行。当炉渣出现并且超过操作员定义的数量时,警报将自动被触发。该系统旨在确保准确地实时检测钢/渣,不受装载重量的影响,无需操作员的干预。

    炉渣检测系统是 AMETEK Land 用于监测和减少钢铁生产设施中的炉渣残留的理想解决方案。事实证明,它可以减少炉渣残留,节省成本并提高作业安全性。


  • 技术参数 +


    SDS 摄像机装置
    测量范围: 800 1800 °C / 1472 3272°F
    图像分辨率: 640 x 480 像素
    光谱响应: 3.9 μm(中心)
    帧速率: 50 /
    探测器: 微测辐射热计焦平面阵列
    光学装置: 12° x 9° / 43° x 33°
    对焦范围: 4 m / 13.1 英尺至无穷大
    保护窗口: 蓝宝石(作为备件提供)
    精度: 测量值的 ±2
    温度分辨率: 0.5°C / 0.9°F800°C / 1472°F 黑体温度)
    外壳: 带隔热罩的水冷和空气净化外壳
    观测管: 其设计大大降低了液态钢/金属直接撞击视野的风险
    尺寸: 560 x 215 x 235 mm / 22 x 8.5 x 9.3 英寸
    重量: 10 kg / 22.05 lbs.
    防护等级: IP 65
    SDS 摄像机供应源
    接口: 摄像机装置和图像处理系统之间的本地连接接口
    服务: 水、仪表空气、电源输入,位于外壳后部
    电源装置(PSU)
    组件和连接:
    光纤数据连接(选配)
    电源、以太网通信(交换机)
    IP 等级: IP65 / NEMA 4
    尺寸: 380 x 380 x 211 mm / 15 x 15 x 8.3 英寸
    重量 :
    15kg / 33.07 lbs.
    UL 认证:
    通过 UL508A 和 CSA-C22.2 认证,文件号为 E499440
    图像处理单元
    炉渣/钢检测: 当在规定的窗口内检测到预设百分比的炉渣或钢/金属时,将发出警报
    用户显示: 首页信息显示和位置标识符。外部数据通过接口输入显示。
    自动功能:
    自动排渣检测、流跟踪、钢/渣比、热视频和视频文件录制、包括排渣编号在内的所有数据的日志文件、钢/渣百分比的清晰显示(条形、数字和图表)、警报颜色等
    软件: IMAGEPro-SDS - 高级图像处理和应用软件
    接口:
    开放数据接口,Modbus TCPMoxa I/O 单元
  • Frequently Asked Questions +


    Question Answer 
    What is a slag detection system and what does it do? The LAND SDS (Slag Detection System) is a proven thermal imaging system that automatically detects the transition from steel to slag during tapping, enabling operators to terminate the tap at the optimal moment. Using a high-resolution 640 × 480 pixel MWIR thermal imaging camera with specialized 3.9 µm spectral filtering to see through smoke and fumes, the SDS delivers improved yields, higher-quality steel and reduced downstream processing costs—with typical slag depth reductions of up to 25% compared to traditional methods.
    How does the LAND SDS actually detect slag during tapping? As the tap runs, the SDS camera continuously images the pouring stream and the dedicated ImagePro-SDS software calculates the live ratio of steel to slag, plotting it on a real-time graph. Because slag and steel radiate differently at the 3.9 µm wavelength, the system distinguishes the two regardless of charge weight. A built-in stream-tracking function keeps the measurement locked on the stream even if it shifts. Once slag exceeds the operator-defined threshold, an automatic alarm fires—and the system can be wired to stop the tap directly.
    Can SDS see through the smoke and fume in a melt shop? Yes—that's a key design advantage. The SDS uses the MWIR-640-SDS camera operating at 3.9 µm wavelength, specifically chosen because it cuts through the smoke, dust, particles and hot gases present during tapping that would blind visible or LWIR cameras. Combined with the 640 × 480 pixel high-resolution detector and up to 60 fps frame rate, operators get a clear, usable thermal image of the tapping stream even in the harsh, dirty conditions typical of BOF and EAF melt shops.
    Does SDS work on both BOF and EAF, and on other metals? Yes—the SDS is designed for operators of secondary steelmaking vessels including Electric Arc Furnaces (EAF), Basic Oxygen Furnaces (BOF) and stainless steel operations. It's also proven in non-ferrous smelting for copper, platinum and other metals. The system measures steel/slag transition independent of charge weight and without operator intervention, adapting well across different vessel types and tapping routines. Hundreds of installations worldwide demonstrate its reliability across diverse operations.
    How much slag carryover can SDS realistically reduce? In practice, plants using SDS have documented slag depth reductions of up to 25% compared to traditional visual stream monitoring. This translates directly to: reduced downstream processing time and materials, improved steel quality and consistency, extended ladle refractory life through reduced slag attack, and improved plant throughput and operating margins. The consistent, automatic detection improves operator response time and removes human variability at end-of-tap—where most slag carryover occurs.
     How does SDS integrate with our plant systems and what data does it record?  SDS runs on LAND's Image Pro-SDS software and connects through open, industry-standard interfaces—Open Data Interface, Modbus TCP/IP, OPC UA and configurable I/O modules—integrating with existing automation and Level 2 systems. It outputs real-time slag/steel percentages, alarm status and sensor health at up to 60 fps. For every tap, the system automatically logs data files and archives thermal video for quality control. Remote viewing is available anywhere on the plant network.

  • 视场 +


    距离 4m  5m 7.5m  1m  15m 
      宽度 高度 IFOV  宽度 高度 IFOV  宽度 高度 IFOV  宽度 高度 IFOV  宽度 高度 IFOV 
    12° x 9° 0.8m 0.6m 1.3mm   1.0m 0.7m 1.6mm 1.5m 1.1m 2.3mm 2.1m 1.5m 3.3mm 3.1m 2.3m 4.8mm
    43° x 33°   3.2m 2.4m 4.9mm 3.9m 2.9m  6.1mm 5.9m  4.4m 9.2mm 7.8m 5.9m 12.2mm 11.8m 8.8m 18.4mm

  • 视频 +

  • 文档 +

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