E-Thesis 233 views
Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System / IVAN POPOV
Swansea University Author: IVAN POPOV
DOI (Published version): 10.23889/SUThesis.68364
Abstract
Basic Oxygen Steel (BOS) making method, requires large quantities of liquid iron (frequently exceeding 300 t) to be poured inside the steel-making furnaces. This operation utilises hot metal (HM) ladles and overhead gantry cranes to perform the pouring action. Due to the large quantities of liquid m...
| Published: |
Swansea University, Wales, UK
2024
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| Institution: | Swansea University |
| Degree level: | Doctoral |
| Degree name: | EngD |
| Supervisor: | Griffiths, C. |
| URI: | https://cronfa.swan.ac.uk/Record/cronfa68364 |
| Abstract: |
Basic Oxygen Steel (BOS) making method, requires large quantities of liquid iron (frequently exceeding 300 t) to be poured inside the steel-making furnaces. This operation utilises hot metal (HM) ladles and overhead gantry cranes to perform the pouring action. Due to the large quantities of liquid metal, this operation poses significant safety concerns associated with metal spillage. When metal is poured, heat emissions are released. These can damage the surrounding components (such as crane ropes), consequently reducing their lifecycles. Automation of this pouring process can reduce the likelihood of metal spillage while also allowing for optimised ladle movement to reduce the generation of heat emissions. Given the hazardous nature of this operation, robust testing and evaluation of automated crane pouring movements is required. 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 to 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 joint frictional components. The flow rate of HM is predicted through the application of a dynamic model, allowing the modelling of system dynamics due to differences in HM pouring weights. Several pouring control schemes were developed and tested using this DT model. These control schemes aim at reducing the generation of heat emissions during HM pouring. These were based on an analysis conducted to study the releases of flame during HM pouring through the application of colour-based image segmentation from videos of the process, drawing relationships between process factors and the generation of flame. Using the developed DT model and conducted analysis, recommendations are made for future process improvements. Here, this calls for control of HM pouring rates in accordance with type of scrap metal used. |
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| Item Description: |
A selection of content is redacted or is partially redacted from this thesis to protect sensitive and personal information. |
| Keywords: |
Digital Twin, Multi-body Dynamics, Dynamic System, Basic Oxygen Steelmaking, Hot Metal Pouring, Friction Estimation, Flow Estimation, Video Analysis, Image Segmentation, Process Optimisation, Process Automation, Control System. |
| College: |
Faculty of Science and Engineering |
| Funders: |
Tata Steel UK, European Social Fund via the Welsh Government (c80816) |