Automation Solutions for Ladle Gate Applications SEAISI 2009, Kuala Lumpur

Key Aspects for Automation Introduction Content Key Aspects for Automation Introduction Automation on Casting Platform Key aspects Automation of Ladle Gate Preparation Casting platform Summary and Outlook Ladle gate preparation The paper reviews the main driving aspects for automation and overviews existing and upcoming automation solutions with focus on the casting platform and on the ladle preparation area. Summary and Outlook May, 2009

Introduction Automation in today’s steel industry Content Automation in today’s steel industry Introduction Increasing demand for automation solutions Safety, process reliability and costs Key aspects Casting platform INTERSTOP’s contribution Automation solutions to complement INTERSTOP’s flow control systems Focus on automation-ready process solutions Ladle gate preparation The demands of today’s steel industry for automation solutions throughout the entire process line are increasing rapidly. The principal driving forces are operator safety, process reliability, and costs. We are developing automation solutions to complement our INTERSTOP flow control systems of ladle gates, tundish gates as well as converter tap hole gates in close cooperation with RHI AG. Stopinc’s and RHI’s main focus is to provide automation-ready process solutions for both, mechanics and refractories. Summary and Outlook May, 2009

Solution to ensure safety Key Aspects for Automation Content Safety Introduction Dangerous tasks Key aspects on casting platform at ladle prep area Casting platform Coupling of casting cylinder Handling of ladle shroud O2-lancing Break out of refractory Handling of heavy loads Ladle gate preparation With regard to operational safety of the ladle gate equipment, special attention must be paid to the casting platform and the ladle preparation area. On the casting platform The first task for the operator on the casting platform to prepare the ladle for casting is the coupling and locking of the ladle gate cylinder to the ladle gate on the turret. Further common activities to be carried out underneath the ladle are the coupling of the slag detection connection and the coupling of the cooling media. Working besides the ladle the operator is exposed to sudden splashes of liquid steel or slag and of steel residuals. More obvious is the danger and the harsh conditions for the operators when coupling the ladle shroud to the exchangeable nozzle of the ladle gate. Besides steel and slag splashes, the exposure to heat and the awkward position of the ladle gate at this stage above the tundish makes manual coupling of the ladle shroud extremely dangerous. At the ladle prep area However, whilst safety is the main focus on the casting platform, the safety requirements in comparison at the ladle preparation area are of minor importance due to the absence of liquid steel. Nevertheless, O2 lancing and breaking out refractory parts produce splashes, fumes, and dust. In addition, the manual handling of heavy loads and high heat radiation lead to harsh working conditions. Therefore, operators at the ladle preparation area are exposed to the potential risk of injury or face severe health problems in the long term. Automation Considering these issues, automation is the solution to ensure safety for the operators. Solution to ensure safety Summary and Outlook Automation May, 2009

Key Aspects for Automation Content Process reliability Introduction At ladle prep area Key aspects Reduced quality due to harsh working conditions Operational safety issues Casting platform Financial issues Ladle gate preparation Process reliability The demanding working conditions for operators at the ladle preparation area can lead to a reduction in the quality of tasks performed. For example incorrect setting of the ladle gate refractories can cause a liquid steel breakout in the worst case, which is not only hazardous to the equipment but can also be fatal for the operating personnel. Careless O2 lancing, insufficient nozzle cleaning, or improper refractory setting can also reduce the lifetime of the refractory components resulting in a…financial issue. Financial issues The cost saving potential at the ladle preparation area is based on a reduction of operating personnel and the benefits due to improvements in process reliability. However, whilst the cost savings due to manpower reduction can be easily quantified, the cost saving potential of higher process reliability can only be estimated qualitatively. Automation Again, automation is the solution to improve process reliability and to reduce total costs. Cost reduction Cost savings Summary and Outlook Automation May, 2009

Automation on Casting Platform Content Manual coupling of casting cylinder Introduction Common practice: Key aspects Casting platform With INTERSTOP’s SNAP coupling: Ladle gate preparation Mounting Coupling Release Manual coupling of the ladle gate cylinder The operators work to couple the casting cylinder to the ladle gate includes a manual insertion of the casting cylinder flange to the ladle gate cylinder bracket. Simultaneously, the operator adjusts the position of the casting cylinder piston rod to the position of the ladle gate push rod by hydraulically controlling the piston rod via a pendant. INTERSTOP’s SNAP coupling Again, the operator inserts the casting cylinder flange manually to the cylinder bracket. For the coupling process the SNAP coupling is pushed forward by the cylinder to catch the push rod. Decoupling is performed by moving out the cylinder sideways The well established SNAP coupling technology fulfils the requirements of a reliable, easy to apply connection ideally. The SNAP coupling is an innovative solution for a safe coupling to the push rod. It is in operation at several steel plants for an easy manual coupling of the casting cylinder on the casting platform and of the mounting cylinder at the ladle preparation area. Summary and Outlook May, 2009

Automation on Casting Platform Content Manual coupling of casting cylinder Introduction Key aspects Casting platform Ladle gate preparation The cylinder head is equipped with two claws of the SNAP coupling. The proved concept is based on the complementary set-up of spring forces, claw geometries and materials. Summary and Outlook May, 2009

Automation on Casting Platform Content Automatic coupling of casting cylinder Introduction State-of-the-art Key aspects Worldwide first fully automatic ladle gate handling system SSAB Tunnplat, Lulea, Sweden INTERSTOP together with MTAG Marti-Technology Casting platform Ladle gate preparation State-of-the-art The first fully automatic coupling of the casting cylinder at SSAB Tunnplat in Lulea, Sweden makes use of a customized, purely mechanical centring system. The manipulator is fixed on the ladle turret arm and swivels the casting cylinder underneath the ladle by 90°, where the SNAP coupling attaches to the push rod of the ladle gate. This handling concept is a joint development of INTERSTOP and MTAG Marti-Technology and is successfully in operation since 2005. The base for the automatic coupling to the push rod is the previously described SNAP coupling The position detection and the positioning of the casting cylinder is purely mechanical and designed to the customer needs. Summary and Outlook Base for automatic coupling is the SNAP coupling Position detection and positioning purely mechanical May, 2009

Automation on Casting Platform Content Automatic coupling of casting cylinder Introduction Near future applications Key aspects Casting platform Robotic handling solutions e.g. LiquiRob® by Siemens VAI Ladle gate preparation Near Future applications Since the commissioning of the first fully automatic ladle gate handling system in 2005, robotic handling solutions on the casting platform have become state-of-the-art for measuring, sampling and applying powder at the tundish. Along with that, optical systems for position detection have been further developed and are now available for robotic solutions e.g. LiquiRob® by Siemens VAI. Therefore, the range of tasks carried out by robots will include automatic coupling of the casting cylinder to the cylinder bracket in the near future. For this application too, the SNAP coupling provides an easy and reliable connection to the push rod. Summary and Outlook Base for automatic coupling is SNAP coupling Position detection and positioning by robot May, 2009

Automation on Casting Platform Content Automatic coupling of ladle shroud Introduction State-of-the-art Key aspects Manually operated or semi-automatic manipulators Manipulator remains connected during casting Casting platform Future application Ladle gate preparation Handling by automatic handling system e.g. robotic solution Ladle shroud clamping device as part of the ladle gate State-of-the-art Driven by safety requirements for the operators, the ladle shroud handling, using manually operated or semi-automatic manipulators, is state-of-the-art. The ladle shroud manipulators are brought to the final position manually controlled by a joystick. Further, the manipulator remains connected to the ladle shroud during casting and applies a defined upward force on the ladle shroud to seal against the exchangeable nozzle. The manipulator axes are released to allow horizontal displacement in order to prevent any lateral forces on the exchangeable nozzle due to the ladle gate movements. Despite this, remaining lateral forces reportedly cause problems at the connection ladle shroud - exchangeable nozzle leading to break out’s at the exchangeable nozzle. Future application The ladle shroud is transferred by a automatic handling system to a specially designed ladle shroud clamping device which is part of the ladle gate. The clamping device is driven by a separate drive which allows a very accurate definition of the force to press the ladle shroud to the exchangeable nozzle. Together with modern ladle gates featuring only two main parts, the ladle shroud clamping device remains relative to the exchangeable nozzle always at the same position. This allows a very simple and reliable design of the ladle shroud clamping device. Summary and Outlook May, 2009

Automation on Casting Platform Content Automatic coupling of ladle shroud Introduction Key aspects Casting platform Ladle gate preparation The advantages of integrating such clamping device into the ladle gate are: No external influences to the connection ladle shroud – exchangeable nozzle such as lateral forces. Clearly defined force for pressing the ladle shroud against the exchangeable nozzle. The handling device stays available for other tasks during casting. This is important for applications of robotic solutions on the casting platform. This system was originally developed by Siemens VAI and has been adapted by Stopinc to INTERSTOP’s ladle gate CS. A joint development of Siemens VAI and Stopinc will allow for the entire ladle shroud clamping device to be coupled to the ladle gate in order to reduce the number of attached parts of the ladle gate. Summary and Outlook May, 2009

Automation of Ladle Gate Preparation Content Current situation Introduction Harsh working conditions at ladle prep areas Operators exposed to fumes, dust and high temperatures Exhausting tasks for operators Key aspects Casting platform Ladle gate preparation The ladle preparation area is often neglected in steel plants, despite its utter significance for safe ladle operation within the steelworks. Typically, it is located where there are harsh working conditions and as a result, the operators are exposed to fumes, dust, and high temperatures. Moreover, the tasks for the operators to perform are exhausting and rather disregarded compared to the tasks on the casting platform. Consequently, incorrect ladle gate preparation can lead to a refractory lifetime reduction and, in the worst case, to severe breakouts. Furthermore, incomplete work at the ladle preparation area may cause significant economic losses, since an unclosed ladle gate leaving the ladle preparation area will lead to a loss of liquid steel at the tapping station. Therefore, in addition to the typical costs of labour and infrastructure, additional costs arise due to such incidents, as well as the potential danger to operating personnel. Risk of Reduced refractory lifetime Breakouts Summary and Outlook May, 2009

Automation of Ladle Gate Preparation Content Vision - Automation System Introduction All tasks to be automated Modular concept Key aspects Casting platform Requirements Ladle gate preparation Vision Based on these issues, a fully automated ladle preparation was envisioned, whereby all tasks at the ladle preparation area from changing the exchangeable nozzle to replacing the purging plugs (or even gunning the ladle), are reliably carried out by a robotic system. Modular concept A modular concept comprising stand-alone systems, for example to change the inner nozzle or clean the casting channel, can be installed at existing ladle preparation areas; however, the full potential of the automation tools is only realized with the complete automation system. Requirements Automation-ready equipment and task-specific tool design provides the possibility to adapt the functional range to the customer’s requirements. Here, the equipment, the experience and the know-how of INTERSTOP and RHI comes in with the aim to provide outstanding solutions for our customers. A standard 6 axis industrial robot is supplied by our automation partner. Automation-ready equipment Specifically developed tools Summary and Outlook Robotic solution by automation partner May, 2009

Automation of Ladle Gate Preparation Content Sequence of ladle preparation Introduction Responsibility Tasks Operator System Key aspects Start Position detection Casting platform Scenario independent tasks Ladle gate preparation Refractory check Sequence The responsibility remains with the operator. The tasks are carried out by the system. After the ladle is placed at the preparation area the maintenance is started by the operator. In the first step, the ladle’s actual position in the ladle stand is detected. This information is used for all the tasks to be performed. Subsequently, the basic tasks required to prepare all ladles, for example cleaning (i.e., O2 lancing) the casting channel and testing the purging plugs, are performed. The next step is for the operator to check the condition of the refractory parts. This check is performed in the same way as today and the operator specifies the parts to be replaced and then selects the appropriate maintenance program. Subsequently, the system performs the relevant tasks such as changing the plates or inner nozzle. After the system has completed the necessary tasks the ladle is assessed and released by the operator. Choose scenario Summary and Outlook Scenario dependent tasks Check & Release May, 2009

CS ladle gate designed to adapt all features Automation of Ladle Gate Preparation Content Automation-ready ladle gate Introduction Mounting cylinder with SNAP coupling Key aspects Casting platform Easy tension release Large access to refractory parts Ladle gate preparation Simple plate centring A requirement for effective automation of the ladle preparation area is the use of automation-ready equipment, namely the INTERSTOP CS ladle gate. This type of ladle gate offers a variety of benefits for robotic systems including that the mounting cylinder with SNAP coupling enables easy connection to the push rod of the ladle gate. With the modern INTERSTOP ladle gates, the tension can be automatically released using the extra stroke of the mounting cylinder. Therefore, no additional device, tool, or further action by the robot is required. After the system tension is released, the ladle gate can be opened directly by the robot. The design of the CS type ladle gate with only two main parts and a large swivelling range provides sufficient access to the refractory parts. Due to the canned refractory plates and the CS ladle gate centring system, the plates can be easily placed into the ladle gate and no additional actions by the robot are required. These examples explicitly demonstrate the specific advantages of the INTERSTOP state-of-the-art CS ladle gate for automation of the ladle preparation area. Summary and Outlook CS ladle gate designed to adapt all features May, 2009

Automation of Ladle Gate Preparation Content Advantages Introduction Cost savings due to higher process reliability Cost reduction due to less operational efforts Increased operational safety Potentially dangerous tasks performed by the automation system Improved quality management Key aspects Casting platform Ladle gate preparation Advantages The following advantages are offered by an automation system: Cost savings due to higher process reliability All tasks are performed in repeatedly high quality, 24 hours a day. Cost reduction due to less operational efforts A reasonable return on invest (ROI) is achieved by a reduction of labour costs. Increased operational safety is achieved due to constant high quality of the ladle preparation. Potentially dangerous tasks for operators such as O2 lancing or handling of heavy loads are performed by the automation system. The accomplishment of performed tasks is recorded and can be statistically used for quality management issues. Summary and Outlook May, 2009

Summary and Outlook Automation for ladle gate application Content Automation for ladle gate application Introduction Ladle gate specific task are due for automation in the near future Driving features are safety, process reliability and financial aspects Stopinc and RHI focus on solutions based on INTERSTOP’s automation-ready equipment In short term robotic solutions on casting platform will be operational In mid term INTERSTOP’s vision of the ladle prep area will become reality Key aspects Casting platform Ladle gate preparation Automation for ladle gate application Ladle gate specific task are due for automation in the near future Driving features are safety with focus on the casting platform, process reliability and financial aspects at the ladle prep area Stopinc and RHI focus on solutions based on INTERSTOP’s SNAP coupling and automation-ready CS ladle gate In short term robotic solutions on the casting platform will be operational In mid term we are determined to realise our vision of an automation solution for the ladle prep area Summary and Outlook May, 2009

INTERSTOP’s Vision Content Introduction Key aspects Casting platform Ladle gate preparation Summary and Outlook May, 2009

Thank you for your attention Content Introduction Key aspects Thank you for your attention Casting platform Ladle gate preparation Summary and Outlook End May, 2009