Reduction in the formation of skulls in Iron ore extraction

Theme: Quantum Tech

Expected Pilot Duration - 3 Months

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Challenge Summary

Molten steel/iron is transferred out using a ladle & skulls are formed in the ladle due to rapid cooling and spillage during pouring. Reducing the loss from skull formation creates benefits in output ratio and volume.

Challenge Scenario

When the raw materials are loaded on to the furnace they undergo a high thermal melting process and attain the molten state. This molten steel/iron has to be transferred to different places for further processing which are usually carried out by the giant ladles. When molten steel is tapped out of the ladle they undergo rapid cooling and form skulls within the walls of the ladle. A lot of spillage also occurs when they are poured out in the pig casting molds causing the skull to be thrown away onto the floor and they pick up dust and solidify making them unusable and recyclable without reprocessing. Preventing skull formation by careful handling and maintaining the ladle temperature will increase total volume output by 1-2%.

Profile of the end users

Coal Oven Team

Furnace Operation Team: Maintain the ladle temperature closer to the molten temperature of the furnace & manual operation of Ladle tilter leads to more spillages while pouring.

Solution Requirements

Monitoring - The ladle has to be monitored for temperature and cooling effects

Maneuvering - Secure maneuvering and guided system to avoid spillage. Leverage IOT to balance ladle tilting operation and Pig Casting machine operation.

Heating - The Ladle can be heated externally to maintain temperature

Timed Intervention - Estimation of timing to complete the entire transfer process based on real time parameters to reduce TAT

Has to integrated to existing crane system

The ladles need to have a retrofittable solution

Ensure full safety of operation as it involves hot metal

Installation - The solution must withstand high operating temperature of the ladle

Personal Risk - The personnel on the floor should not be affected to any automation

Deployment - The system should have safety critical features to protect personnel on the floor

Expected Outcomes

1. Quantified Metrics & Outcomes:
Operational KPIs/Metrics Current Value Expected Target Value
Overall Skull reduction 3-4% 1-2%
2. Qualified Outcomes:
Operational KPI/Metrics Current State Expected Target State
3. ESG Impact:
ESG Metric Expected Value/State

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