In the steelmaking industry, timing is everything. The Slag Detection System (Slag Detector) is one of the most advanced solutions based on Machine Vision and Industrial AI, designed to accurately identify the exact moment slag enters the molten steel flow. By providing real-time monitoring, this system prevents impurities from entering downstream processes and guarantees the quality of the final product.
The carryover of slag into the tundish or casting mold is the primary cause of several critical issues:
Severe reduction in the metallurgical quality of the steel.
Formation of non-metallic inclusions in the final product.
Serious damage to sensitive equipment and increased maintenance costs.
By detecting this phenomenon early, the Slag Detector plays a key role in process control and the elimination of human error.
Utilizing heat-resistant industrial Thermovision cameras, the system analyzes the characteristics of the molten stream in harsh environmental conditions. Intelligent algorithms make decisions based on the following parameters:
Optical Spectrum Analysis: Identifying changes in color and brightness intensity between the melt and the slag.
Stream Texture Analysis: Detecting instability and turbulence in the output flow texture.
Motion Patterns: Monitoring the temporal fluctuations and behavioral patterns of the molten flow.
By integrating this data, the system identifies the critical Transition phase and issues the necessary commands.
As soon as slag is detected, the system can automatically execute the following responses:
Direct Command to PLC: Rapidly closing the Slide Gate.
Intelligent Alerting: Activating visual and audible alarms for the operator.
Data Logging: Precisely recording events, timing, and images for statistical analysis and reporting.
Implementing machine vision technology in this sector offers numerous economic and technical advantages:
Quality Assurance: Reducing inclusions and improving the mechanical properties of the steel.
Equipment Protection: Preventing nozzle erosion and unplanned production shutdowns.
Material Optimization: Reducing the consumption of ferroalloys and ladle refining costs.
Elimination of Operator Error: Transforming visual monitoring into a precise Process Control system.
The Slag Detector can be installed at all strategic melt discharge points:
Electric Arc Furnace (EAF) tapping.
Converter tapping (BOF / LD).
Ladle to Tundish flow in Continuous Casting Machines (CCM).
The Slag Detection system offers one of the fastest Return on Investment (ROI) rates in heavy industry automation. Preventing just a few “defective heats” or unplanned line stoppages can cover the total project cost within a few months. This system is not merely an expense, but a strategic investment to increase profitability.
At Dorsa, our Slag Detector systems are custom-designed based on the specific requirements of each production line. Key features of our solutions include:
Seamless integration with industrial automation systems and PLCs.
Proprietary image processing algorithms optimized for high-dust and high-heat environments.
Technical support and software customization tailored to the specific metallurgy of the plant.
Dorsa: Leading the way in Steel Industry Intelligence and Process Control through Machine Vision.
