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Development of a liquid measurement and management system at the OneSteel

Whyalla Blast Furnace
Authors
R. Keil, J. Tsalapatis, Arrium Steel OneSteel Whyalla Steelworks, Australia
Contact data
John Tsalapatis
OneSteel Whyalla Steelworks
PO Box 21, Whyalla, 5600 South Australia, Australia
Telephone: +61 8 8640 4017
Mobile phone: +61 40 969 4791
Email: john.tsalapatis@onesteel.com

Summary

OneSteels Whyalla Steelworks in South Australia is a fully integrated plant which operates a single blast furnace.
Following a number of years of in-house continuous development within Ironmaking, a comprehensive liquid
measurement system has been established which incorporates a novel iron on-torpedo weighing technique and
slag liquid measurement system. This system which includes torpedo tracking at key locations of the Whyalla
Steelworks has been in full plant operational use for over six years. Throughout this time it has been providing a
suite of reliable liquid measurement and management information to both the Ironmaking and Steelmaking
departments.
The system features provide the ability to accurately measure, in real-time, the amount of liquid iron and slag cast
at the blast furnace. The continuous state of liquid accumulation is understood by incorporating these direct
measurements with a number of models of liquids generated in the furnace. Aside from blast furnace liquid
accumulation information, casting rates of iron and slag, torpedo locations and batch-weights at the blast furnace
and basic oxygen steelmaking plant, other useful information is also available. This data includes the torpedo
empty-weight, dead-weight, the torpedo carrying-capacity (an important measure for tracking the refractory wear or
skulls in a torpedo vessel), as well as independent accurate tonnes of hot metal poured at Steelmaking and hot
metal dumping stations. The time since the torpedo was last filled is also provided; this relative age of stored iron
is a key input into the torpedo movement and steelmaking pacing program.
An automatic calibration routine of the on-torpedo weighing system exists, which uses as the standard reference
the hot metal weighbridge at Steelmaking.
This paper details the development history, the design concept and the operational implementation of this
integrated blast furnace liquid measurement and management system.

Key words

Blast furnace, BOS, liquid measurement, casting, liquid iron, slag, liquid accumulation.

Introduction

Original weighing system concept

A key element in controlling the blast furnace and

maintaining a stable process, is knowing how many
tonnes of liquids are cast and at what rate. Actions
can be taken, based on this information for control of
the blast furnace process by managing the liquid
accumulation. High liquid levels in the furnace
severely affect the gas distribution, permeability and
stability of the furnace, which in turn affects the
product chemistry, variability and temperature.

Prior to the development of a liquid measurement

system, operators on the cast house floor visually
estimated the iron and slag casting rates. This
required experience and guesswork and was
dependent on the cleanliness and condition of the
torpedo and slag pots.

The criticality of having accurate and timely liquid cast

weights becomes greater as the blast furnace
production increases and the cast liquid volumes
approach the limits of hearth capacity.
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An experimental system of liquid iron weighing on the

torpedo was developed at the Whyalla Blast Furnace
in the mid-1980s with the then Works Research
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Department. This system involved measuring linear
displacement of the torpedo body as it filled with liquid
metal. This displacement could be extrapolated to
infer an amount of hot metal in the torpedo. For that
experimental system the torpedoes were plugged in

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and the measurement was communicated to a PLC.

This later became a wireless system.
The experimental system results were calibrated
against the certified weight as measured at the
Steelmaking (BOS) hot metal weighbridge. Accuracy
of the on-torpedo measurement was found to be 5
tonnes. However the system was labour and
maintenance intensive due to the required regular
manual adjustment of calibration factors to keep the
extrapolation calculation accurate. For short periods
of time the system worked very well, and it was
believed that if all the concerns were addressed, a
reliable system with very useful information could be
established.

In 2006, the previous experimental system was

completely revamped. The new measurement system
is based on the previous experience, and incorporates
modern electronic components and new features. An
exceptionally reliable system has been developed.
This system is more comprehensive than the
experimental system, as it includes liquid slag
measurement, allowing integration with the on line
liquid accumulation scheme. The system has now
been in full operation for over six years and has been
providing reliable liquid measurement and
management information to both Ironmaking and the
Steelmaking departments.

Current Whyalla Blast Furnace cast house

floor layout

The blast furnace at Whyalla has two cast house

floors and there are two torpedo filling positions on
each floor, with the iron flow controlled by a tilting
spout. Each torpedo in the Whyalla fleet has a
nominal hot metal capacity of 200 tonnes. The slag
filling stations on each floor also have a tilting spout to
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direct the flow of slag into either of two 30m slag pots
(Figure 3).
The guns and drills have an automatic operating
mode with the tapping and gunning data linked to
accumulation models. The drill automation records the
taphole length, opening times and drill velocity
throughout the taphole opening. The clay gun
activities are also recorded in detail, with all hydraulic
pressures, clay pushed rates, times and clay volumes
being logged. At Whyalla we aim for a dry hearth
casting practice with an alternate taphole use.

Hot metal weighing system details

Torpedo identification:
Each torpedo is equipped with an identification tag,
mounted on a pole, which is positioned to be directly
in front of a tag reader when in a filling or pouring
position.
Identification of the torpedoes is achieved with a RFID
tag reader system (radio-frequency identification).
Eight RFID tag readers are installed, one at each of
the four blast furnace filling positions, one at each of
the three BOS pouring positions, and one on the line
to the hot metal dump pits. These tag readers
communicate with the dedicated blast furnace PLC.

Summary of the current weighing system

features

The torpedo weighing system is installed and active

on all torpedos.
The torpedo weights are inferred from linear
displacement of torpedo body (spring deflection).
The batch weight accuracy is required to be 5
tonnes within a 0 to 300 tonnes range.
The system calculates and displays the iron filling
rate at each of the four filling positions at the blast
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furnace with an accuracy of better than 0.2

tonnes/minute in the range of 0 to 5 tonnes/minute.
This fill rate is smoothed to show a realistic casting
rate.
A large display is positioned on the cast house floor,
on which can be viewed the torpedo number, the
filling position, the batch weight and the filling rate.
The liquid measurement system is integrated with
the existing control network and display system, so
the operators can monitor all features remotely from
any control station, including at Steelmaking.
The iron liquid measurement system is designed to
minimise maintenance requirements with an
availability of the equipment of greater than 98%.
A torpedo tracking system keeps track of which
torpedoes are in the filling positions at the blast
furnace, and which torpedoes are on any of the
three BOS hot metal weighbridges, as well as the
tonnes of hot metal in those positions.
The weighing system on each torpedo is
automatically calibrated at each of the four filling
positions at the blast furnace. This is achieved by
comparing the filled weight with the measured iron
weight at the BOS weighbridge.
Hot metal weights and torpedo IDs are collected at
the BOS and wirelessly transmitted back to the blast
furnace liquid measurement PLC for this calibration
to occur.
The system gives the time elapsed since each filled
torpedo left the blast furnace, to assist the
Steelmakers determine which iron to use first.
The system gives a leaving weight of each torpedo
as it is taken off the BOS hot metal weighbridge,
indicating the amount of remaining hot metal if any
is returned to the blast furnace.
The system gives an empty-weight of each torpedo
(dead-weight) as it leaves the BOS weighbridge
allowing accurate long term tracking of the worn or
sculled condition of the torpedo.
The system tracks torpedoes which have been to
the hot metal dump pit and automatically resets the
torpedo weight to zero.
In addition to the iron weighing system, a real time
liquid slag measurement system has also been
installed using level measurement radars.

The tag readers under the blast furnace cast floor are
connected via a DeviceNet network to the PLC. The
tag readers at the BOS site and dump pit line are
connected to a separate DeviceNet network, and the
signal transmitted back to the blast furnace weighing
system PLC.

blast furnace divided by the BOS hot metal

weighbridge net weight (gross arrival weight minus the
previous leaving dead-weight).
When a set number of valid paired blast furnace filling
and BOS pouring data is obtained, a calibration is
performed automatically.
Blast furnace Cast House Floor Information
Display:
A display is provided on the cast house floor in a
position that is clearly visible to the operators on the
floor. The display shows the torpedo number and the
position under that cast house floor. The batch weight
and the filling rate of each torpedo in position under
that casting floor is also available on the display.

Figure 1: Installation of weighing system components

on the torpedo ladle.
Weight measurement:
Mounted on one corner of each torpedo is a LVDT
(linear vertical displacement transducer), and a striker
is positioned to measure the compression of the
springs. These LVDTs are robust and operate reliably
in the harsh environment of high vibration, heat and
shock levels. They have excellent repeatability and
high accuracy. Each LVDT is mounted in a dust
resistant stainless steel box.
The position signal from the LVDT is scanned once
every 10 seconds (to conserve battery life) and a
radio transmits the signal to the iron weighing PLC
where it is converted into tonnes. The battery and
radio are housed in a double skinned box, mounted
on the torpedo structure.
When the system is enabled, the system remains in
the vacant state until the RFID detection routine
detects a torpedo is in position. The system will then
proceed to the in position state and remain in this
state until a steady rise in weight is detected. At this
stage the system will proceed into the filling state
and weight increases are recorded.
Torpedo filling position calibration:
The weight calibration block is used to calibrate the
on-torpedo LVDT weight measurement against the
certified BOS hot metal weighbridge weight
measurement.
Paired fill / pour measurements for every torpedo and
each filling position are incorporated in the automatic
calibration. A conversion factor is calculated for each
torpedo and filling position. This conversion factor is
the ratio between the LVDT measured weight at the

Figure 2: Cast house floor liquid measurement

display.
Control system displays:
There are numerous liquid measurement displays and
trends available in the control system, accessible
across the plant. Most of the trends can be viewed in
a one second time frame to help analyse activities. A
liquid measurement overview display shows in real
time the cast house floor tapping activities with cast
batch weights, fill rates and casting activity times for
the iron and slag.

Figure 3: Overview of the blast furnace casting

activities
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Maintenance of the hot metal weighing

system

Torpedo Tracking:
A tracking display is used to monitor the location of all
the torpedoes at key locations on the plant with the
tonnes of iron in each. This display only shows
torpedoes in locations of filling and pouring positions,
if between these positions it is shown in the unknown
location column. GPS is not used at this stage to
show torpedoes in transit. A total available hot metal
tonnes in the system is shown and trended.

Batteries are changed approximately once a month

and a check is made at the time for obvious
equipment faults. All parts of the system are made of
rugged high quality components in order to resist the
harsh conditions of heat and vibration. The housing
for the battery and radio is a double skinned box to
give maximum protection for these components.

Liquid slag real time measurement

Simultaneous to the development of the hot metal

measurement system, a conventional liquid slag
measurement system was also installed. The slag at
the Whyalla Blast Furnace is cast into steel pots, and
taken with Kress carriers to a location remote from
the furnace for dumping into slag pits.
Slag measurement system equipment details:
The system consists of four Saab Rosemount radar
units on the slag station roof, one above each slag pot
position. Radars are installed so that slag flow does
not interrupt radar beam and each radar installation is
nitrogen purged for maximum unit life.
An algorithm inside the liquid measurement PLC can
calculate the slag liquid volume from the height of slag
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in the pot. The accuracy is 0.5m of the slag volume
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in the range of 5 to 30m . The software takes into
account the shape of the steel slag pot and due to the
irregular flow of slag, a fill rate smoothing routine is
used.
The system can determine if a slag pot is present, the
amount of debris in the pot, the real time level of liquid
slag and convert this information to the volume of cast
slag and filling rate. The slag measuring system is
integrated with the existing plant control network.
The slag measuring system has minimal maintenance
requirements with availability of greater than 99%.

Figure 4: Plant wide torpedo tracking display.

The following points are the main features of this
display:
The display indicates the tonnes of iron in all
torpedoes throughout the plant and displays a trend
of the total tonnes at any time.
Time since last filling age of iron
The torpedo tracking display has a column indicating
the age of iron, which is a count up timer from the
time the torpedo left the blast furnace filling position.
This is particularly useful to the steelmakers when
sequencing the torpedo use so the oldest iron is used
first and overall hot metal management.
Torpedo carrying-capacity
This is an important measurement for tracking
refractory wear or sculling of a torpedo vessel. It
shows the current weight of iron that can be held by
each torpedo. It is based on the arrival weight on the
BOS weighbridge of a full torpedo minus the previous
leaving empty-weight.

Liquid accumulation models

The continuous state of liquids generated in the blast

furnace is understood by incorporating the direct liquid
iron and slag cast measurements into furnace liquid
accumulation models.
Two independent calculations of the liquid balance of
the furnace are performed.

Pouring at the BOS

Charge based scheme:

In this scheme the volume of liquids produced is
calculated using the rate at which raw materials are
charged into the furnace. The accumulation value is
the difference between the liquids produced by the
charged materials and the measured liquids cast.

When a torpedo arrives at the BOS it is shunted onto

a weighbridge, where the tag reader picks up the
torpedo number. The net weight is calculated and
displayed by automatically taking the previous emptyweight of that torpedo away from the gross arrival
weight on the weighbridge. The weighbridge weight
is an accurate certified weight, so is used to calibrate
the LVDT on each torpedo.

Injectants based scheme:

An alternative method of calculating liquids
accumulated is based on the current furnace
injectants and average rate at which the injectants
generate liquids. This calculation provides a better
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Abbreviations

indication of the liquids accumulating during a

charging delay.

LVDT: Linear vertical displacement transducer

RFID: Radio frequency identifier
BOS: Basic oxygen steelmaking
PLC: Programmable logic controller
TREADWELLS: Hot metal torpedo ladle

In Figure 5 below the two methods of calculating

accumulation are trended (the yellow trace is based
upon the injectants scheme and the red trace is based
upon the charging scheme). Good agreement is
evident between both calculations. Interestingly, also
displayed in this trend is the hearth EMF trace (green
trace), which is based on different measurement
principles.

Acknowledgements

The authors wish to acknowledge all the members of

the project team consisting of Bob Keil, John
Tsalapatis, Gregg Winson, Stefan Kerec, Danny
Garde, Craig Foulkes, Matthew Middleton, Bevan
Daniels and LogiCamms who made the liquid
measurement system a reality.

References

[1] Simonds, B.: Report No. WR299 Hot metal

weighing interim report; BHP Whyalla Works
Research Department, 1986.

Figure 5: Liquid accumulation trends.

Conclusion

An iron and slag measurement system was designed

and built from scratch in Whyalla. For this project all
the electronic equipment had to be trialled and proven
suitable on the plant in this application. The liquid
measurement system automatically measures the iron
and slag as they are cast from the furnace. The iron
system is based on measurement of the torpedo
spring deflection during filling whereas the slag
system is radar level based. The software, electronic
computerised displays and the torpedo tracking
system were also designed and developed in-house
at Whyalla. Team members in the blast furnace
technology and electrical engineering group, wrote the
logic required to trend the liquid accumulation in the
hearth of the blast furnace, integrating the real time
information from the liquid measurement system.
The ability to continuously track the tonnes of iron
around the plant and monitor torpedo movements has
given Whyalla Blast Furnace and Steelmaking
operators an understanding not possible in the past.
The ability to monitor the condition of torpedoes
assists with the refractory maintenance programme
and can potentially prevent a torpedo breakout.
The reliability of the equipment has been the key to
the success of the project, giving confidence in the
data provided and a better understanding of the actual
hearth liquid levels. This in turn assists to manage the
casting and furnace stability.

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