Digital twin model of a large scale hot molten metal ladle pouring system

POPOV, IVAN; Griffiths, Christian

doi:10.1007/s00170-024-13739-w

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Digital twin model of a large scale hot molten metal ladle pouring system

IVAN POPOV, Christian Griffiths

The International Journal of Advanced Manufacturing Technology, Volume: 133, Pages: 491 - 506

Swansea University Authors: IVAN POPOV, Christian Griffiths

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DOI (Published version): 10.1007/s00170-024-13739-w

Abstract

In steel-making processes, large quantities (frequently exceeding 300 t) of liquid metal are transferred between vessels. In Basic Oxygen Steel (BOS) making process, metal is poured from Hot Metal (HM) ladles, utilising overhead gantry cranes, into furnaces for further processing. Due to the large q...

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Published in:	The International Journal of Advanced Manufacturing Technology
ISSN:	0268-3768 1433-3015
Published:	Springer Nature 2024
Online Access:	Check full text
URI:	https://cronfa.swan.ac.uk/Record/cronfa66396
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first_indexed	2024-05-13T08:48:59Z
last_indexed	2024-05-13T08:48:59Z
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spelling	v2 66396 2024-05-13 Digital twin model of a large scale hot molten metal ladle pouring system 2d8cadf14779ac092cf553be0690f967 IVAN POPOV IVAN POPOV true false 84c202c256a2950fbc52314df6ec4914 Christian Griffiths Christian Griffiths true false 2024-05-13 In steel-making processes, large quantities (frequently exceeding 300 t) of liquid metal are transferred between vessels. In Basic Oxygen Steel (BOS) making process, metal is poured from Hot Metal (HM) ladles, utilising overhead gantry cranes, into furnaces for further processing. Due to the large quantities of liquid metal poured, this operation poses significant safety concerns associated with metal spillage and releases of heat emissions. This can further lead to damage being caused to surrounding infrastructure. Pouring automation can reduce the likelihood of metal spillage, optimising ladle movement for reduction in heat emission releases. Given the hazardous nature of this operation, robust testing and evaluation of automated crane pouring movements is required prior to their application. A digital twin (DT) model of an overhead gantry crane/HM ladle system is presented here, intended to provide a safe testing environment for controlled pouring movement and serve as a testbed for control system design studies. Accurate crane movement is achieved using multi-body dynamics, solving for non-linearities present due to rigid joint frictional components. The flow rate of HM is estimated through the application of a dynamic model, allowing the modelling of system dynamics due to differences in HM pouring weights. The devised DT model is evaluated by simulating real crane movement and making a comparison on the resultant changing HM weight inside the ladle. The devised DT removes the need for construction of a physical model or performing tests directly on the HM pouring system. Journal Article The International Journal of Advanced Manufacturing Technology 133 491 506 Springer Nature 0268-3768 1433-3015 Basic oxygen steelmaking; Hot metal pouring; Digital twin; Friction estimation; Flow estimation; Multi-body dynamics; Dynamic system 1 7 2024 2024-07-01 10.1007/s00170-024-13739-w COLLEGE NANME COLLEGE CODE Swansea University SU Library paid the OA fee (TA Institutional Deal) European Social Fund via the Welsh Government (c80816) 2024-10-21T11:19:06.3381279 2024-05-13T09:46:14.8372298 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering IVAN POPOV 1 Christian Griffiths 2 66396__30448__be3df5d964364581a6b916f33a640100.pdf 66396.pdf 2024-05-22T18:13:16.9471972 Output 2034710 application/pdf Version of Record true © The Author(s) 2024. This article is licensed under a Creative Commons Attribution 4.0 International License. true eng http://creativecommons.org/licenses/by/4.0/
title	Digital twin model of a large scale hot molten metal ladle pouring system
spellingShingle	Digital twin model of a large scale hot molten metal ladle pouring system IVAN POPOV Christian Griffiths
title_short	Digital twin model of a large scale hot molten metal ladle pouring system
title_full	Digital twin model of a large scale hot molten metal ladle pouring system
title_fullStr	Digital twin model of a large scale hot molten metal ladle pouring system
title_full_unstemmed	Digital twin model of a large scale hot molten metal ladle pouring system
title_sort	Digital twin model of a large scale hot molten metal ladle pouring system
author_id_str_mv	2d8cadf14779ac092cf553be0690f967 84c202c256a2950fbc52314df6ec4914
author_id_fullname_str_mv	2d8cadf14779ac092cf553be0690f967_*_IVAN POPOV 84c202c256a2950fbc52314df6ec4914_*_Christian Griffiths
author	IVAN POPOV Christian Griffiths
author2	IVAN POPOV Christian Griffiths
format	Journal article
container_title	The International Journal of Advanced Manufacturing Technology
container_volume	133
container_start_page	491
publishDate	2024
institution	Swansea University
issn	0268-3768 1433-3015
doi_str_mv	10.1007/s00170-024-13739-w
publisher	Springer Nature
college_str	Faculty of Science and Engineering
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hierarchy_parent_title	Faculty of Science and Engineering
department_str	School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
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description	In steel-making processes, large quantities (frequently exceeding 300 t) of liquid metal are transferred between vessels. In Basic Oxygen Steel (BOS) making process, metal is poured from Hot Metal (HM) ladles, utilising overhead gantry cranes, into furnaces for further processing. Due to the large quantities of liquid metal poured, this operation poses significant safety concerns associated with metal spillage and releases of heat emissions. This can further lead to damage being caused to surrounding infrastructure. Pouring automation can reduce the likelihood of metal spillage, optimising ladle movement for reduction in heat emission releases. Given the hazardous nature of this operation, robust testing and evaluation of automated crane pouring movements is required prior to their application. A digital twin (DT) model of an overhead gantry crane/HM ladle system is presented here, intended to provide a safe testing environment for controlled pouring movement and serve as a testbed for control system design studies. Accurate crane movement is achieved using multi-body dynamics, solving for non-linearities present due to rigid joint frictional components. The flow rate of HM is estimated through the application of a dynamic model, allowing the modelling of system dynamics due to differences in HM pouring weights. The devised DT model is evaluated by simulating real crane movement and making a comparison on the resultant changing HM weight inside the ladle. The devised DT removes the need for construction of a physical model or performing tests directly on the HM pouring system.
published_date	2024-07-01T11:19:05Z
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Digital twin model of a large scale hot molten metal ladle pouring system

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