Title

LADLE OPENING RATE – DEPENDING ON PRODUCT, PROCESS AND PERSONNEL

Ladle Opening Rate – Depending on Product, Process and Personnel

Authorship

HILGENHÖNER, ENNO; BOMBECK, MARC ANDRÉ; HAUKE, KERSTIN; DANNERT, CHRISTIAN; BOEKE, AXEL; ALMEIDA, LEANDRO PEIXOTO

HILGENHÖNER, ENNO

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BOMBECK, MARC ANDRÉ

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HAUKE, KERSTIN

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DANNERT, CHRISTIAN

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BOEKE, AXEL

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ALMEIDA, LEANDRO PEIXOTO

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DOI

10.5151/2594-5300-42368

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Abstract

Purpose of the well filler is to protect and seal the casting channel during ladle transport and treatment and to freely and safely open when the slide gate is opened in casting position. The opening rate is measured in [%], comparing the number of successful free opening ladles vs the ones that require lancing. That means, numbers between 0-100% opening rate are possible. Steel making statistics reveal a specific well filler amount of 0,3-0,5 kg applied per t of crude steel. In this paper the question of the global scale of non-free opening is put on the table. For example, assuming an average global opening rate of e.g., 90% leads already to 2.000-2.800 ladles per day, that require lancing. Lancing means operational safety hazards, slow process, and quality downgrades. In a nutshell: high risk at high costs. One of the key factors in this scenario is certainly the suitability of the well filler. However, our recent observation in ladle preparation area show that the automation and monitoring rate is rather low. Also, individual process, metallurgical, and application aspects are not always considered. Weebotec has therefore developed the 3 P concept (product, process, personnel) to support a more holistic approach for increased ladle opening rates together with the customer. For the product well filler, selection of raw materials, degree of purity and professional processing are of importance. Reproducibility of the desired sintering behavior, flowability and infiltration with respect to steel must be ensured. In steel plants, knowledge of all important process parameters such as process route, heat size, idle time etc. is necessary to develop suitable well fillers. Finally, well filler application is a relevant influencing factor. Providing the correct amount in the right place at the right time is crucial. Best results are achieved by using modular dosing stations. Certainly, precise, and reproducible working standards for de-slagging and reliable ladle hygiene in the ladle preparation/tilting area are mandatory. In this publication, operational laboratory tests will reveal how the 3 P concept has already proven that simple adjustments to process, application technology and product contributed to an increased ladle opening rate [1].

PURPOSE OF THE WELL FILLER IS TO PROTECT AND SEAL THE CASTING CHANNEL DURING LADLE TRANSPORT AND TREATMENT AND TO FREELY AND SAFELY OPEN WHEN THE SLIDE GATE IS OPENED IN CASTING POSITION. THE OPENING RATE IS MEASURED IN [%], COMPARING THE NUMBER OF SUCCESSFUL FREE OPENING LADLES VS THE ONES THAT REQUIRE LANCING. THAT MEANS, NUMBERS BETWEEN 0-100% OPENING RATE ARE POSSIBLE. STEEL MAKING STATISTICS REVEAL A SPECIFIC WELL FILLER AMOUNT OF 0,3-0,5 KG APPLIED PER T OF CRUDE STEEL. IN THIS PAPER THE QUESTION OF THE GLOBAL SCALE OF NON-FREE OPENING IS PUT ON THE TABLE. FOR EXAMPLE, ASSUMING AN AVERAGE GLOBAL OPENING RATE OF E.G., 90% LEADS ALREADY TO 2.000-2.800 LADLES PER DAY, THAT REQUIRE LANCING. LANCING MEANS OPERATIONAL SAFETY HAZARDS, SLOW PROCESS, AND QUALITY DOWNGRADES. IN A NUTSHELL: HIGH RISK AT HIGH COSTS. ONE OF THE KEY FACTORS IN THIS SCENARIO IS CERTAINLY THE SUITABILITY OF THE WELL FILLER. HOWEVER, OUR RECENT OBSERVATION IN LADLE PREPARATION AREA SHOW THAT THE AUTOMATION AND MONITORING RATE IS RATHER LOW. ALSO, INDIVIDUAL PROCESS, METALLURGICAL, AND APPLICATION ASPECTS ARE NOT ALWAYS CONSIDERED. WEEBOTEC HAS THEREFORE DEVELOPED THE 3 P CONCEPT (PRODUCT, PROCESS, PERSONNEL) TO SUPPORT A MORE HOLISTIC APPROACH FOR INCREASED LADLE OPENING RATES TOGETHER WITH THE CUSTOMER. FOR THE PRODUCT WELL FILLER, SELECTION OF RAW MATERIALS, DEGREE OF PURITY AND PROFESSIONAL PROCESSING ARE OF IMPORTANCE. REPRODUCIBILITY OF THE DESIRED SINTERING BEHAVIOR, FLOWABILITY AND INFILTRATION WITH RESPECT TO STEEL MUST BE ENSURED. IN STEEL PLANTS, KNOWLEDGE OF ALL IMPORTANT PROCESS PARAMETERS SUCH AS PROCESS ROUTE, HEAT SIZE, IDLE TIME ETC. IS NECESSARY TO DEVELOP SUITABLE WELL FILLERS. FINALLY, WELL FILLER APPLICATION IS A RELEVANT INFLUENCING FACTOR. PROVIDING THE CORRECT AMOUNT IN THE RIGHT PLACE AT THE RIGHT TIME IS CRUCIAL. BEST RESULTS ARE ACHIEVED BY USING MODULAR DOSING STATIONS. CERTAINLY, PRECISE, AND REPRODUCIBLE WORKING STANDARDS FOR DE-SLAGGING AND RELIABLE LADLE HYGIENE IN THE LADLE PREPARATION/TILTING AREA ARE MANDATORY. IN THIS PUBLICATION, OPERATIONAL LABORATORY TESTS WILL REVEAL HOW THE 3 P CONCEPT HAS ALREADY PROVEN THAT SIMPLE ADJUSTMENTS TO PROCESS, APPLICATION TECHNOLOGY AND PRODUCT CONTRIBUTED TO AN INCREASED LADLE OPENING RATE [1].

Keywords

Steelmaking, Clean Steel, Ladle Opening, Well Filler, Free Opening

Steelmaking, Clean Steel, Ladle Opening, Well Filler, Free Opening