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Application of Thermal Cameras in Ladle Detection

In recent years, serious accidents such as high-risk burning, fire, explosion, etc., in the process of ironmaking and steelmaking in metallurgical industry have frequently occurred due to overheating of molten steel (iron) and breakdown of ladle, serious abrasion of ladle lining and fatigue damage, which has posed serious threat to production safety. Using thermal cameras to achieve online rapid detection and diagnosis can timely detect abnormal temperature changes of devices, locate defective parts, avoid safety accidents in time and ensure normal production and operation.

I. Main Applications of Thermal Cameras in Ladle Detection

1. Detecting the lining of ladle and tundish

Due to chemical erosion, mechanical erosion and rapid cooling and heating, the ladle lining is prone to cracks, bulges, and falling off. When the local damage of refractory materials is serious and undetected, it will cause serious breakout accidents. Thermal cameras can detect the damage of lining and avoid accidents.

2. Detecting ladle and tundish slag

Slag will not only reduce the quality of molten steel, but also easily block the tapping hole, accelerate the abrasion of ladle refractory layer and shorten the service life of devices. Since the temperature of slag and molten steel are obviously different, the position of slag can be detected by real-time output of temperature image by thermal cameras.

3. Detecting the temperature of molten steel
Due to the harsh environment of ladle and high temperature characteristics of molten steel, traditional temperature measurement methods can hardly measure the temperature of molten steel in real time. Thermal cameras can measure the temperature of molten steel in real time, automatically and continuously, analyze the changing trend of molten steel temperature according to the generated temperature curve, so that maximum temperature and average temperature of molten steel can be displayed directly, which provides a strong basis for production management and process improvement.

II. Unique Advantages of Thermal Cameras in Ladle Detection

1. Non-contact, all-weather and real-time monitoring does not affect the normal operation of the ladle

2. The highest temperature point, highest temperature, and average temperature of a measured area are displayed, without the need of measuring the temperature at single points. This facilitates the operator to obtain information

3. The software automatically generates temperature change curve records, captures images of the onsite situation, and displays the temperature in the heat treatment

4. The device supports high-temperature point alarms. You can set multi-level alarm thresholds. If the temperature reaches a threshold, the alarm signals will be provided

III. Recommended Models

AT31/61 Electric Focusing Online Temperature Measurement Thermal Camera

Automatic focusing: more convenient field application

PoE power supply: simplified cabling

Comprehensive software functions: linkage with external alarm devices

AT31F/61F Fixed Focusing Online Temperature Measurement Thermal Camera

Wide-angle lens: no dead angle for target detection

I/O alarm output: linkage with external alarm devices

SDK for multiple platforms: supporting secondary development

AT31U Online Ultra-High Temperature Thermal Camera

Wide temperature measurement range from 0°C to 1500°C, which meets the high temperature monitoring application requirements

3.3mm wide-angle fixed-focus lens: comprehensive temperature distribution display

SDK provided: easy integration, flexible development

IV. Software Solution

It is recommended to use with InfiRay’s professional temperature measurement and monitoring system:

Real-time display: The full radiation heat map is displayed in real time, so that on-duty personnel can view the temperature at any location, record, photograph and analyze the abnormal situation, and issue a professional test report.

Temperature tracking: It can automatically analyze the temperature rise trend of the whole thermal image or a specific area, generate a temperature curve, and discover potential safety hazards in advance.

Data capture: The thermal imaging data can be collected regularly for later analysis.

Shooting and alarm triggered due to high temperature: The monitoring background can detect abnormal temperatures in time and trigger alarms. The audible and visual alarm module will give alarms and the background will take pictures during the incident.

Support for networking of multiple devices: Connection of multiple devices to the software platform by networking so that these devices can be displayed on the platform; the preview of real-time images and videos

V. How to Take an Infrared Thermal Image of Premium Quality?

Please refer to the following suggestions for using a thermal camera to take a thermal image of premium quality:

1. Select thermal cameras with high thermal sensitivity for scenarios with a small regional temperature difference

2. Select thermal cameras or levels of proper measurement ranges for different scenes and temperature

3. Use automatic measurement first, and then enable the temperature width stretch function. Manually set the temperature width to the minimum and include the previously measured temperature range to enrich the image details

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