Iron and steel industry

Thermography is a high-value tool for steel production, it not only guarantees the quality of the product but also the safety of the operators. Furnace inspection, casting, fill level are some of its applications.

The portfolio of tools that integrates bcbMonitor 4.0 makes it a high-performance instrument that ensures repeatability and traceability, as well as cost reduction due to reduced waste.

bcbMonitor 4.0 as a high technology thermographic platform has allowed the integration of multiple projects within the steel industry for continuous supervision and monitoring of its processes.

Applications

There are two main processes for the production of steel, by means of a blast furnace where the coal reduces the iron ore to form a “hot metal” and the electric arc furnace that uses scrap steel that is melted and alloyed to produce the metal. liquid.

We can find steel in practically all sectors, such as in construction, in machines, in the automotive sector, in the railway industry, etc. This leads the producers of this material to face challenges not only to comply with the production, but also to maintain the quality of the product and the safety of the site.

The bcbMonitor 4.0 software family together with thermal cameras provides reliable and non-destructive solutions that adapt to the high demands of this sector.

bcbMonitor 4.0 solutions:

Monitoring of filling level in the pot.
Slag detection in pot and distributor.
Continuous inspection of electrodes and electric arc buses

bcbFireScan solutions:

Detection of hot spots in electric arc furnace (EAF) and basic oxygen furnace (BOF).

Continuous casting not only offers a high level of productivity and performance, but also an improved quality. Research and development are intensively worked in foundry field, because the requirements of customers on the quality of steel become more and more stringent and important, as well as energy efficiency, productivity and ecological aspects.

Using systems based on thermography allows optimizing continuous casting processes and improving not only the condition of the product, but also energy consumption in steel mills. Having a system such as the bcbMonitor 4.0 allows obtaining infrared images that provide an optimal analysis of the heat flow. This is a way to ensure uniform cooling in the product, which is key to improve the quality of the process, and thus:

  • Detect discontinuities (cracks)
  • Maintain dimensional control in slab and billet.

Incinerators, furnaces, crucibles and boilers are used in a wide variety of industries, burning liquid and solid fuels. For maximum energy efficiency and thermal insulation, refractory linings must be as porous as possible and resist slag penetration and wear damage. The useful life of such linings in an industrial incinerator can be less than two years and the costs of replacement, waste disposal and production interruption can be very high.

A leak from these containers and the spilling of liquid metal in a plant would be a completely catastrophic event. Continuous monitoring of refractories such as buckets and torpedo cars is important and this can be achieved through thermographic monitoring.

The bcbMonitor 4.0 is capable of detecting wear in refractories, warning of critical areas where a leak or spill may occur. This powerful software enables continuous and unattended inspection of:

  • Thermo carts (Torpedo)
  • BOF and EAF ovens
  • Ladles, pots,
  • Distributors and other containers

The minerals or raw materials are transported to the furnace by conveyor systems. It is one of the essential equipment in the production process of mines, refineries and factories and therefore ensuring its optimal condition is a priority for the company. Despite this importance, these inspections cannot be done frequently because they involve a plant stoppage.

On the other hand, the humidity in the transported materials is dangerous. When it reaches the furnace, it can cause an explosive reaction, causing great losses, production stoppages as well as endangering the plant personnel.

For both applications, the bcbMonitor 4.0 thermal imaging system is invaluable. It allows detecting the moisture in the minerals and alerting the operators prior to their arrival at the kiln, as well as generating a report of the continuous and non-invasive evaluation of the conveyor belt to detect:

  • Fissures,
  • Agglomerations
  • Detachment
  • Cable exposure

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