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Anais do Seminário de Aciaria, Fundição e Metalurgia de Não-ferrosos

ISSN 2594-5300

44º Seminário de Aciaria — vol. 44, num.44 (2013)

Título

THE TECHNOLOGY, BENEFITS, AND MEASUREMENT OF THE ELBYTM LADLE BOTTOM

THE TECHNOLOGY, BENEFITS, AND MEASUREMENT OF THE ELBYTM LADLE BOTTOM

Autoria

Toner, Andy; Boeing, John; Teixeira, Alberto; Dainton, Albert

Toner, Andy
Toner, Andy

Eu sou esse autor

Boeing, John
Boeing, John

Eu sou esse autor

Teixeira, Alberto
Teixeira, Alberto

Eu sou esse autor

Dainton, Albert
Dainton, Albert

Eu sou esse autor

DOI

10.5151/2594-5300-22777

Downloads

533 Downloads

Resumo

The ELBYTM (Enhanced Ladle Bottom Yield) system is a novel technology for a steel teeming ladle precast bottom that uses specifically designed channels, terraces, and impact zones to alter the phenomenon of vortexing at the end of the ladle draining sequence. By delaying the vortex, more steel is allowed to exit the ladle into the tundish without slag carryover. In actual operations, the ELBYTM system can potentially achieve large yield savings which impact the operating cost of the steel plant. Significant technical benefits are also gained by insuring less slag carryover into the tundish, resulting in lower tundish maintenance costs and improved steel quality. The ELBYTM system is made possible through three proprietary technologies: Computational Fluid Dynamics (CFD): After a detailed audit is conducted on the ladle practice, a CFD is utilized to study and simulate the ladles draining pattern, vortex characteristics, and surface collapse. CFD analysis will detail the specific design of the ELBYTM bottom and estimate the yield savings.NUMAXTM Refractory Castable: Cement free refractory, ultra low water castable. Designed with optimal particle packing, NumaxTM castable allows ELBYTM ladle bottoms to maintain their engineered profile to maximize flow characteristics and yield savings.Infrared Thermal Imaging (ITI): The measurement of yield savings is very important to the steelmaker. Using a proprietary infrared measurement system, videos are taken of individual ladle dumps after casting. Specialized software distinguishes slag steel, labeling each with a unique color. A program specifically designed for the ELBYTM system counts the total number of pixels in both the slag and steel to give a percentage of each component.In summary, the combination of bottom design, NumaxTM castable performance, and infrared yield measurement make the ELBYTM system an important innovation with the potential to impact shop yield around the world.

 

The ELBYTM (Enhanced Ladle Bottom Yield) system is a novel technology for a steel teeming ladle precast bottom that uses specifically designed channels, terraces, and impact zones to alter the phenomenon of vortexing at the end of the ladle draining sequence. By delaying the vortex, more steel is allowed to exit the ladle into the tundish without slag carryover. In actual operations, the ELBYTM system can potentially achieve large yield savings which impact the operating cost of the steel plant. Significant technical benefits are also gained by insuring less slag carryover into the tundish, resulting in lower tundish maintenance costs and improved steel quality. The ELBYTM system is made possible through three proprietary technologies: Computational Fluid Dynamics (CFD): After a detailed audit is conducted on the ladle practice, a CFD is utilized to study and simulate the ladles draining pattern, vortex characteristics, and surface collapse. CFD analysis will detail the specific design of the ELBYTM bottom and estimate the yield savings.NUMAXTM Refractory Castable: Cement free refractory, ultra low water castable. Designed with optimal particle packing, NumaxTM castable allows ELBYTM ladle bottoms to maintain their engineered profile to maximize flow characteristics and yield savings.Infrared Thermal Imaging (ITI): The measurement of yield savings is very important to the steelmaker. Using a proprietary infrared measurement system, videos are taken of individual ladle dumps after casting. Specialized software distinguishes slag steel, labeling each with a unique color. A program specifically designed for the ELBYTM system counts the total number of pixels in both the slag and steel to give a percentage of each component.In summary, the combination of bottom design, NumaxTM castable performance, and infrared yield measurement make the ELBYTM system an important innovation with the potential to impact shop yield around the world.

Palavras-chave

Ladle; Yield; Technology; Caster; Refractory.

Ladle; Yield; Technology; Caster; Refractory.

Como citar

Toner, Andy; Boeing, John; Teixeira, Alberto; Dainton, Albert. THE TECHNOLOGY, BENEFITS, AND MEASUREMENT OF THE ELBYTM LADLE BOTTOM , p. 238-244. In: 44º Seminário de Aciaria, São Paulo, 2013.
ISSN: 2594-5300 , DOI 10.5151/2594-5300-22777

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in StreamHandler.php line 131
at HandleExceptions->handleError(8, 'fwrite(): write of 1826 bytes failed with errno=28 No space left on device', '/var/www/webroot/ROOT/vendor/monolog/monolog/src/Monolog/Handler/StreamHandler.php', 131, array('stream' => resource, 'record' => array('message' => 'file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', 'context' => array('exception' => object(ErrorException)), 'level' => 400, 'level_name' => 'ERROR', 'channel' => 'production', 'datetime' => object(DateTime), 'extra' => array(), 'formatted' => '[2025-06-01 02:52:13] production.ERROR: file_put_contents(): write of 328 bytes failed with errno=28 No space left on device {"exception":"[object] (ErrorException(code: 0): file_put_contents(): write of 328 bytes failed with errno=28 No space left on device at /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php:122)[stacktrace]#0 [internal function]: Illuminate\\\\Foundation\\\\Bootstrap\\\\HandleExceptions->handleError(8, \'file_put_conten...\', \'/var/www/webroo...\', 122, Array)#1 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php(122): file_put_contents(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', 2)#2 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/FileSessionHandler.php(83): Illuminate\\\\Filesystem\\\\Filesystem->put(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', true)#3 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Store.php(128): Illuminate\\\\Session\\\\FileSessionHandler->write(\'jIK30MAvFzgnCSC...\', \'a:5:{s:6:\\"_toke...\')#4 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Middleware/StartSession.php(87): Illuminate\\\\Session\\\\Store->save()#5 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(218): Illuminate\\\\Session\\\\Middleware\\\\StartSession->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#6 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(189): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminateMiddleware(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#7 /var/www/webroot/ROOT/public/index.php(59): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#8 {main}"} ')))
at fwrite(resource, '[2025-06-01 02:52:13] production.ERROR: file_put_contents(): write of 328 bytes failed with errno=28 No space left on device {"exception":"[object] (ErrorException(code: 0): file_put_contents(): write of 328 bytes failed with errno=28 No space left on device at /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php:122)[stacktrace]#0 [internal function]: Illuminate\\\\Foundation\\\\Bootstrap\\\\HandleExceptions->handleError(8, \'file_put_conten...\', \'/var/www/webroo...\', 122, Array)#1 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php(122): file_put_contents(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', 2)#2 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/FileSessionHandler.php(83): Illuminate\\\\Filesystem\\\\Filesystem->put(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', true)#3 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Store.php(128): Illuminate\\\\Session\\\\FileSessionHandler->write(\'jIK30MAvFzgnCSC...\', \'a:5:{s:6:\\"_toke...\')#4 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Middleware/StartSession.php(87): Illuminate\\\\Session\\\\Store->save()#5 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(218): Illuminate\\\\Session\\\\Middleware\\\\StartSession->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#6 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(189): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminateMiddleware(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#7 /var/www/webroot/ROOT/public/index.php(59): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#8 {main}"} ')in StreamHandler.php line 131
at StreamHandler->streamWrite(resource, array('message' => 'file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', 'context' => array('exception' => object(ErrorException)), 'level' => 400, 'level_name' => 'ERROR', 'channel' => 'production', 'datetime' => object(DateTime), 'extra' => array(), 'formatted' => '[2025-06-01 02:52:13] production.ERROR: file_put_contents(): write of 328 bytes failed with errno=28 No space left on device {"exception":"[object] (ErrorException(code: 0): file_put_contents(): write of 328 bytes failed with errno=28 No space left on device at /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php:122)[stacktrace]#0 [internal function]: Illuminate\\\\Foundation\\\\Bootstrap\\\\HandleExceptions->handleError(8, \'file_put_conten...\', \'/var/www/webroo...\', 122, Array)#1 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php(122): file_put_contents(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', 2)#2 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/FileSessionHandler.php(83): Illuminate\\\\Filesystem\\\\Filesystem->put(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', true)#3 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Store.php(128): Illuminate\\\\Session\\\\FileSessionHandler->write(\'jIK30MAvFzgnCSC...\', \'a:5:{s:6:\\"_toke...\')#4 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Middleware/StartSession.php(87): Illuminate\\\\Session\\\\Store->save()#5 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(218): Illuminate\\\\Session\\\\Middleware\\\\StartSession->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#6 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(189): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminateMiddleware(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#7 /var/www/webroot/ROOT/public/index.php(59): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#8 {main}"} '))in StreamHandler.php line 117
at StreamHandler->write(array('message' => 'file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', 'context' => array('exception' => object(ErrorException)), 'level' => 400, 'level_name' => 'ERROR', 'channel' => 'production', 'datetime' => object(DateTime), 'extra' => array(), 'formatted' => '[2025-06-01 02:52:13] production.ERROR: file_put_contents(): write of 328 bytes failed with errno=28 No space left on device {"exception":"[object] (ErrorException(code: 0): file_put_contents(): write of 328 bytes failed with errno=28 No space left on device at /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php:122)[stacktrace]#0 [internal function]: Illuminate\\\\Foundation\\\\Bootstrap\\\\HandleExceptions->handleError(8, \'file_put_conten...\', \'/var/www/webroo...\', 122, Array)#1 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php(122): file_put_contents(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', 2)#2 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/FileSessionHandler.php(83): Illuminate\\\\Filesystem\\\\Filesystem->put(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', true)#3 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Store.php(128): Illuminate\\\\Session\\\\FileSessionHandler->write(\'jIK30MAvFzgnCSC...\', \'a:5:{s:6:\\"_toke...\')#4 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Middleware/StartSession.php(87): Illuminate\\\\Session\\\\Store->save()#5 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(218): Illuminate\\\\Session\\\\Middleware\\\\StartSession->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#6 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(189): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminateMiddleware(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#7 /var/www/webroot/ROOT/public/index.php(59): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#8 {main}"} '))in AbstractProcessingHandler.php line 39
at AbstractProcessingHandler->handle(array('message' => 'file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', 'context' => array('exception' => object(ErrorException)), 'level' => 400, 'level_name' => 'ERROR', 'channel' => 'production', 'datetime' => object(DateTime), 'extra' => array(), 'formatted' => '[2025-06-01 02:52:13] production.ERROR: file_put_contents(): write of 328 bytes failed with errno=28 No space left on device {"exception":"[object] (ErrorException(code: 0): file_put_contents(): write of 328 bytes failed with errno=28 No space left on device at /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php:122)[stacktrace]#0 [internal function]: Illuminate\\\\Foundation\\\\Bootstrap\\\\HandleExceptions->handleError(8, \'file_put_conten...\', \'/var/www/webroo...\', 122, Array)#1 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Filesystem/Filesystem.php(122): file_put_contents(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', 2)#2 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/FileSessionHandler.php(83): Illuminate\\\\Filesystem\\\\Filesystem->put(\'/var/www/webroo...\', \'a:5:{s:6:\\"_toke...\', true)#3 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Store.php(128): Illuminate\\\\Session\\\\FileSessionHandler->write(\'jIK30MAvFzgnCSC...\', \'a:5:{s:6:\\"_toke...\')#4 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Session/Middleware/StartSession.php(87): Illuminate\\\\Session\\\\Store->save()#5 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(218): Illuminate\\\\Session\\\\Middleware\\\\StartSession->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#6 /var/www/webroot/ROOT/vendor/laravel/framework/src/Illuminate/Foundation/Http/Kernel.php(189): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminateMiddleware(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#7 /var/www/webroot/ROOT/public/index.php(59): Illuminate\\\\Foundation\\\\Http\\\\Kernel->terminate(Object(Illuminate\\\\Http\\\\Request), Object(Illuminate\\\\Http\\\\Response))#8 {main}"} '))in Logger.php line 344
at Logger->addRecord(400, 'file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', array('exception' => object(ErrorException)))in Logger.php line 707
at Logger->error('file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', array('exception' => object(ErrorException)))in Writer.php line 203
at Writer->writeLog('error', 'file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', array('exception' => object(ErrorException)))in Writer.php line 114
at Writer->error('file_put_contents(): write of 328 bytes failed with errno=28 No space left on device', array('exception' => object(ErrorException)))in Handler.php line 113
at Handler->report(object(ErrorException))in Handler.php line 100
at Handler->report(object(ErrorException))in HandleExceptions.php line 81
at HandleExceptions->handleException(object(ErrorException))