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Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System / IVAN POPOV

Swansea University Author: IVAN POPOV

  • E-Thesis under embargo until: 7th November 2029

DOI (Published version): 10.23889/SUThesis.68364

Abstract

Basic Oxygen Steel (BOS) making method, requires large quantities of liquid iron (frequently exceeding 300 t) to be poured inside the steel-making furnaces. This operation utilises hot metal (HM) ladles and overhead gantry cranes to perform the pouring action. Due to the large quantities of liquid m...

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Published: Swansea University, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Griffiths, C.
URI: https://cronfa.swan.ac.uk/Record/cronfa68364
first_indexed 2024-11-28T13:47:42Z
last_indexed 2025-01-16T20:49:38Z
id cronfa68364
recordtype RisThesis
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spelling 2025-01-16T16:16:54.5428156 v2 68364 2024-11-28 Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System 2d8cadf14779ac092cf553be0690f967 IVAN POPOV IVAN POPOV true false 2024-11-28 Basic Oxygen Steel (BOS) making method, requires large quantities of liquid iron (frequently exceeding 300 t) to be poured inside the steel-making furnaces. This operation utilises hot metal (HM) ladles and overhead gantry cranes to perform the pouring action. Due to the large quantities of liquid metal, this operation poses significant safety concerns associated with metal spillage. When metal is poured, heat emissions are released. These can damage the surrounding components (such as crane ropes), consequently reducing their lifecycles. Automation of this pouring process can reduce the likelihood of metal spillage while also allowing for optimised ladle movement to reduce the generation of heat emissions. Given the hazardous nature of this operation, robust testing and evaluation of automated crane pouring movements is required. A Digital Twin (DT) model of an overhead gantry crane/HM ladle system is presented here, intended to provide a safe testing environment for controlled pouring movement and to serve as a testbed for control system design studies. Accurate crane movement is achieved using multi-body dynamics, solving for non-linearities present due to joint frictional components. The flow rate of HM is predicted through the application of a dynamic model, allowing the modelling of system dynamics due to differences in HM pouring weights. Several pouring control schemes were developed and tested using this DT model. These control schemes aim at reducing the generation of heat emissions during HM pouring. These were based on an analysis conducted to study the releases of flame during HM pouring through the application of colour-based image segmentation from videos of the process, drawing relationships between process factors and the generation of flame. Using the developed DT model and conducted analysis, recommendations are made for future process improvements. Here, this calls for control of HM pouring rates in accordance with type of scrap metal used. E-Thesis Swansea University, Wales, UK Digital Twin, Multi-body Dynamics, Dynamic System, Basic Oxygen Steelmaking, Hot Metal Pouring, Friction Estimation, Flow Estimation, Video Analysis, Image Segmentation, Process Optimisation, Process Automation, Control System. 7 11 2024 2024-11-07 10.23889/SUThesis.68364 A selection of content is redacted or is partially redacted from this thesis to protect sensitive and personal information. COLLEGE NANME COLLEGE CODE Swansea University Griffiths, C. Doctoral EngD Tata Steel UK, European Social Fund via the Welsh Government (c80816) Tata Steel UK, European Social Fund via the Welsh Government (c80816) 2025-01-16T16:16:54.5428156 2024-11-28T11:06:48.9624531 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering IVAN POPOV 1 Under embargo Under embargo 2025-01-16T16:08:53.4653357 Output 8409463 application/pdf E-Thesis true 2029-11-07T00:00:00.0000000 Copyright: The Author, Ivan Popov, 2024 true eng
title Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
spellingShingle Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
IVAN POPOV
title_short Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
title_full Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
title_fullStr Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
title_full_unstemmed Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
title_sort Digital Twin Application for Analysis and Design of an Automated Large Scale Steel Plant Ladle Pouring System
author_id_str_mv 2d8cadf14779ac092cf553be0690f967
author_id_fullname_str_mv 2d8cadf14779ac092cf553be0690f967_***_IVAN POPOV
author IVAN POPOV
author2 IVAN POPOV
format E-Thesis
publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUThesis.68364
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 0
active_str 0
description Basic Oxygen Steel (BOS) making method, requires large quantities of liquid iron (frequently exceeding 300 t) to be poured inside the steel-making furnaces. This operation utilises hot metal (HM) ladles and overhead gantry cranes to perform the pouring action. Due to the large quantities of liquid metal, this operation poses significant safety concerns associated with metal spillage. When metal is poured, heat emissions are released. These can damage the surrounding components (such as crane ropes), consequently reducing their lifecycles. Automation of this pouring process can reduce the likelihood of metal spillage while also allowing for optimised ladle movement to reduce the generation of heat emissions. Given the hazardous nature of this operation, robust testing and evaluation of automated crane pouring movements is required. A Digital Twin (DT) model of an overhead gantry crane/HM ladle system is presented here, intended to provide a safe testing environment for controlled pouring movement and to serve as a testbed for control system design studies. Accurate crane movement is achieved using multi-body dynamics, solving for non-linearities present due to joint frictional components. The flow rate of HM is predicted through the application of a dynamic model, allowing the modelling of system dynamics due to differences in HM pouring weights. Several pouring control schemes were developed and tested using this DT model. These control schemes aim at reducing the generation of heat emissions during HM pouring. These were based on an analysis conducted to study the releases of flame during HM pouring through the application of colour-based image segmentation from videos of the process, drawing relationships between process factors and the generation of flame. Using the developed DT model and conducted analysis, recommendations are made for future process improvements. Here, this calls for control of HM pouring rates in accordance with type of scrap metal used.
published_date 2024-11-07T05:25:16Z
_version_ 1851097682542592000
score 11.444473

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