Steel Industry Solutions Non-Contact Temperature Sensors for Improved Process Monitoring a nd Greater Efficiency

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1 Steel Industry Solutions Non-Contact Temperature Sensors for Improved Process Monitoring a nd Greater Efficiency Developed specifically for high-temperature applications in the steel and primary metal industries Proven reliability in severe production environments Mikron offers the broadest selection of solutions for metal processing, including: High-resolution thermal imagers Ultra-precise single point infrared thermometers (IRTs) 2-color systems 2-wire pyrometers Temperature switches

2 Complete System Solution for P rocess Control Improve Your Process with Better Measurement Today's increasing quality standards and higher energy costs demand more precise temperature control in the steel making process. With almost 40 years experience in temperature measurement, Mikron Infrared is the industry leader in all areas of steel manufacturing control and process monitoring. Our non-contact infrared temperature solutions provide the steel industry with cutting-edge technology, ease-of-use and dependability when monitoring critical parameters for productivity and product quality. These solutions are used throughout the steel manufacturing process, where accurate temperature monitoring is required for control. Optimize Energy Consumption and Output Steel manufacturing consists of high temperature manufacturing steps that use significant amounts of energy. Processes such as coke oven heating, continuous casting, furnace reheating, induction heating, heat treating, forging, sintering and vacuum melting are becoming more and more expensive. With energy prices at all time highs, the cost of doing business has significantly increased. Steel facilities need the right tools to ensure they optimize energy usage across their facilities. Mikron addresses these needs by providing the most accurate measurements in the industry enabling steel facilities to maximize their output. Without this level of accuracy, operators are forced to reheat more often than necessary, wasting valuable time, money and energy. We Know Steel Applications... Coke Ovens Raw Materials Monitoring temperature of coke ensures that the raw materials have achieved the right characteristics, prevents damage to equipment (e.g., conveyor belts) and reduces safety risk. Thermal Imagers:, MCL160 Spot IRTs: M67, MI-5, MI-140 Portable: M7800, M90, MI-8, MI-K315 A constant need for maintaining and tracking coke oven temperatures are critical to the production of coke for the steel industry. Mikron s MI-K315-K portable single-point IRT offers extremely accurate temperature measurements in coke ovens prior to push. The focusable optics and compact design provide easy operation and capture during the measurement process. Mikron s is used to automatically monitor edge-to-edge on a transfer belt to detect true hot spots. Mikron s software and related I/O systems allow for automated process monitoring to reduce equipment downtime.

3 Stove Dome Blast Furnace Continuous scans of stove dome temperatures are required for maintaining correct operation of the blast furnace. Stove domes contain the gases used to heat the blast furnaces and also house the waste gases. These gases can reach temperatures up to 2600 o F and extremely volatile. Historically, manufacturers have used expensive thermocouples to measure the air and refractory wall temperature, but thermocouples degrade and fail frequently under the harsh conditions. Mikron s cooled and purged instrument enclosures provide the highest level of protection in the industry. In comparison to thermocouples, Mikron s non-contact sensors will continue to provide reliable, accurate measurement for many years. Mikron s solutions are made specifically to withstand the extremely harsh environments found in the steel industry. For refractory or wall measurement, the s accuracy and 76,000 points of measurement allow operators to detect the smallest refractory breaks before they cause costly downtime. Thermal Imagers:, MCL160 Spot IRTs: M67, MI-5, MI-140 Portable: M7600, M7800, M90, MI-8, MI-K315 Pre-Heat Ladle Torpedo Cars Ladle Pouring BOF EAF Typical IR applications in the steel industry include routine inspection of metal components such as ladles, torpedo cars and other refractory equipment and components. Engineers need a tool to monitor what s happening within these vessels. Ladle pre-heating is used to keep the refractory brick from cracking when the hot molten steel is poured into a ladle. It also it prevents the molten metal from hardening when it hits a cooler area of the refractory. Steel mills typically use a lid that comes down and blasts fire onto the refractory. This process can take up to 22 hours to complete. Mikron s 3.9µm spectral response spot pyrometers can be mounted on top of the pre-heat ladle lid to see through the flame and down to the bottom of the refractory for accurate temperature measurement. This is a much more accurate and more reliable solution relative to expensive thermocouples that chronically burn out. a more accurate and responsive temperature measurement can reduce ladle preheat time and reduce cost. Consistent monitoring of the exterior of a steel ladle with Mikron s enables the operator to quickly determine if the ladle s refractory needs to be replaced. The engineer is therefore able to predict when a ladle can be reused or should be replaced, which can save thousands of dollars to rebrick the ladle. Finding hot spots also reduces the possibility of molten metal breaking through a torpedo car, which could damage surrounding equipment and lead to loss in production and affect worker safety. Thermal Imager: Spot IRTs: M67, M67S Portable Imager: M7800, M7604

4 Blast and Coke Furnaces Slag Detection When liquid steel is tapped from a basic oxygen (BOF) or electric arc (EAF) furnace, it is advantageous to minimize the quantity of slag carried over into the ladle. Previously this has been done by visual observation of the tapping stream or by the use of electromagnetic induction coils mounted onto the furnace. However, neither of these methods has proven to be entirely reliable. Mikron Infrared supplies the complete system designed specifically for the Steel Industry. Our infrared imagers provide a controlled field of view, aimed at a specific region of the pour as it exits the furnace. The highly precise detectors in the Mikron process thermal imaging cameras detect the variances in the signature radiance of the molten pour. When the signature percentage reaches a preset limit the pour can be terminated. By limiting the pour precisely, the minimum amount of slag is introduced. The length of the pour is also maximized allowing for more workable product for a given amount of energy. Key Product Thermal Imagers:, HF Continuous Casting Continuous casting is the process where the molten steel is cooled and solidified into billets or slabs. The core is still usually molten with a hard outer shell. Molten metal is transferred from the ladle into a tundish, where it is slowly tapped into the casting machine. The mold in which the steel slips into is water cooled. The operator s challenge is to keep the steel within the channel. This can be difficult due to variations in the tundish temperature. Mikron s infrared thermometers accurately measure cooling requirements of slabs, billets or blooms to ensure product uniformity and provide equipment operators with immediate temperature information that is critical to the cooling process. Mikron s pyrometers and imagers gauge the temperature as the molten metal pours down the mold. Mikron has very specific pyrometers and accessories to address the very harsh environment surrounding the casting area. This includes steam, high temperatures and harsh water spray. The pyrometer needs to stay clean and cool in this area. The temperatures help the operators control the speed of the process and the amount of cooling sent through the mold. This helps the quality of the slab and billets. The with its accurate hot-edge detection imaging and temperature profiling capabilities can control continuous casting processes better than any other imaging method currently used. : Thermal Imagers: Two Color Spot IRTs: M770, M77, MI-SQ5, MI-SR12, MI-GA12, MI-SR50-LO

5 Preheat and Ladles Rolling Mills: Slabs, Bars, Billets Infrared sensors measure strip and sheet temperature so that rolling mill stands can be efficiently set to match the steel s temperature. Sensors are used to detect the presence of hot metal to accurately time the roll stand operation. Pyrometers can be used to measure the roll temperature as water cools the roll during the steel quenching process. Steam is an issue with this application, requiring special spectral responses to accurately measure system temperature. Mikron s 9201 and M770 are ideal solutions to ensure uniform temperature and keep the slab within its working temperature range. Mikron s 9201 and M770 selectively control the quench zones so that only the higher temperature part of the slab is quenched to the maximum extent allowed, resulting in greater working time. Thermal Imagers: Two-Color Spot IRTs: M77, M770, MI-SQ5, MI- SR12, MI-GA12, MI-SR50-LO Burr Detection When cutting steel slabs, there is a flow of slag which solidifies as burrs on the underside of the slab. The removal of the burrs is critical. The deburring system may slip over the burrs which are sometimes extremely flat. Current visible systems have not been proven reliable for residual burr detection. The use of Mikron s innovative M thermal imaging system ensures residual burr detection after the slab-cutting process with 100% reliability: Ensure continuous high quality and avoid costly customer complaints. Accurately detect termperature differences between slab and burrs through the use of 76,800-pixel high-resolution cameras. Enable real-time display of image sequences and evaluation of temperature information in specific regions (regions of interest). Transfer data to a higher level control unit for removal of bad slabs from the process (using digital or analog output modules and TPC/IP protocols). Allow for camera installations that are highly configurable in harsh industrial environments. Thermal Imagers: M

6 Annealing Furnaces Annealing is a controlled heating and then cooling process that changes the metal's characteristics. It is often a relatively slow process requiring significant energy. Inaccurate temperature measurement, non-uniform ovens, or poorly sealed furnaces lead to added costs and reduced quality. Thermal imagers and spot IRTs can be used to accurately monitor both product temperature and furnace temperature. Thermal imagers and multiple spot IRTs are used to control uniformity inside furnaces with zone control. Use Mikron s thermal imagers to investigate door seals and external insulation to find leaks and other sources of heat loss which negatively impact energy usage. Mikron's portable thermal imagers combine unparalleled accuracy and ease-of-use. Thermal Imagers: Spot IRTs: M67, MI-5 Portable: M7600, M7800, M90, MI-8 We Deliver Steel Solutions... Enclosures and Accessories Mikron's advanced enclosures are specifically designed to protect the instruments in harsh, high temperature steel environments. The enclosures allow for remote monitoring of temperatures in real time, and for image data to be transferred from one or more cameras to a single PC. The units are insulated and cooled to protect the temperature measurement device and to maximize efficiency, while ensuring safe continuous operation. Our enclosures allow for versatile operations of Mikron equipment with no maintenance requirements. They are also highly configurable and modular to fit almost any environmental need. Process Imaging M9200 (640 x 480) Mikron s M9200 system is designed specifically for steel applications with a narrow band spectral response at the near infrared region which minimizes measurement errors due to variations in target emissivity. Features include: Extremely high accuracy (0.5%) Measures temperature at 300,000 points, 60 times a second Minimally affected by emissivity Sees through glass or quartz view ports 32-channel isolated current outputs for automated process control Versatile image processing software Measures 600 C to 3000 C (320 x 240) The offers unparalleled accuracy for demanding steel applications. With an unmatched array of protective accessories, the demonstrates Mikron s commitment to long-term trouble-free operation of these instruments. Features include: Configurable to work with standard PLCs (OPC based) 30 Hz image update Process control applications in factory production environment NEMA-4 housing (optional) High accuracy ±2% or 2 C of reading Standard long wavelength, less affected by sunlight and factory lighting Available with multiple wavelength configurations Measurements from 200 C to 2000 C Mikron s MikroSpec software programs lead the industry for image collection and data analysis. MCL Series (160 x 120, 320 x 240, 640 x 480) The MCL series offers affordable high performance process imaging with digital image transfer and remote monitoring capabilities. Real time digital image transfer Gigabit ethernet Remote monitoring via Local Area Network No thermo-electric cooler (less power consumption) Measures up to 60 times per second Built-in digital output

7 Some examples of Mikron products for the steel industry. Visit our web site for a complete listing. Spot Infrared Thermometers (IRTs) With over 40 years in non-contact temperature measurement, Mikron offers the industry s broadest selection of IRTs with features designed specifically for high temperature steel processing. Short wavelength (near infrared) provides higher accuracy measurements demanded for precise process control MI-S5 MI-GA5-TV M67 Series Rugged series available in different configurations. Includes a variable focus optical system and extensive protective/mounting hardware accessories. Offered in an FM approved version. Measurement range: -40 C to 3000 C (-40 F to 5400 F) MI-5 Series The 5 Series is a workhorse IRT with versions offered for almost all applications. Compatible with Mikron s extensive line of protective jackets and enclosures making it suitable for the harsh steel processing environment. Versions available with through lens sighting, laser sighting, video sighting, two-color (MI-SQ5), and fiber optics. Measurement range: 600 C to 2500 C (1012 F to 4532 F) MI-S140 The 140 Series is a high accuracy IRT with focusable optics, an integrated user interface, and a variety of sighting options including laser, through lens, or video. Rugged enclosures with cooling and purging are available. Measurement range: 300 C to 3300 C (572 F to 5972 F) M68 Series Rugged fiber optic version of the M67 that allows same quality of measurement in spots that are less accessible or severe. The fiber optic lens can withstand 315 C (600 F) ambient and up to 480 C (900 F when used with companion cooling jacket MI-S50-LO Fiber optic 50 Series is a very fast response (1 ms) instrument with compact optics for easier integration into equipment. The optical head and fiber can withstand ambient temperature up to 250 C (482 F). Also available in an extremely short wavelength version (0.676 µm) for molten metals with high emissivity. Measurement range: 250 C to 3500 C (482 F to 3500 F) MI-P140-LO Unique combination of high accuracy, and low temperature measurement capability in a fiber optic solution. Measurement range: 100 C to 750 C (212 F to 1382 F) Two -Color IRTs Ideal for applications with steam, smoke and dust, our two-color IRTs are also designed to not only survive but also measure accurately in dirty, hot environments. Measurements are unaffected by dust and other contaminants in the field of view or by dirty viewing windows, the temperature measurement is independent of the emissivity of the object in wide ranges, and the measuring object can be smaller than the spot size MI-SQ5 2-Color, laser targeting or through-lens sighting with analog and digital output. Measurement ranges 600 C to 3000 C (1012 F to 5432 F) M770 Fiber optic 2-color digital pyrometer with focusable optics, alarm relay and integrated display. Measurement ranges: 300 to 3500 C (572 F to 6332 F) depending on configuration MI-SR50-LO Optical fiber allows the viewing optics to be easily located in areas with ambient temperatures up to 250 C (482 F). Perfect for rolling mills and other areas with quenching steam. Measurement ranges: 700 C to 3000 C (1292 F to 5432 F) M90 R2 Portable Two-Color IRT ideal for Coke Ovens and Blast Furnaces. Measurement ranges: 900 C to 3000 C (1652 F to 5432 F) Portable Thermal Imager and IRTs Same great performance as our process control solutions, but in convenient, battery powered form M7800 & M7604 Handheld IR Cameras Sturdy and compact, ideal for use on the production floor. Uses a UFPA microbolometer detector Measurement ranges -40 C to 2000 C (M7800) or 1600 C (M7600PRO). M90 Handheld IR Thermometer Uses cutting edge electro-optical technology to provide focusable and through-lens sighting. The circular reticule defines precisely the target spot. Measurement ranges: -40 C to 3000 C depending on model. MI-8 Series Affordable, high temperature short wavelength pyrometer for non-contact temperature measurement of metals. Measurement ranges: 300 to 2500 C MI-K315K Handheld IRT designed specifically for requirements in coke applications. Internal data logger stores 2000 measurement points. Easy to use optics allow focus of a small spot size. Measurement ranges: 600 C to 1600 C

8 Steel Processing Application Mikron Product Process Imaging Portable Sensors Process Control Black Body Coke Ovens Blast Furnaces Mi-K315K MI-GA15+ MI-8 M90Q M90H MI-S50-LO M68 H MI-SR50-LO M78 Ladle / Torpedo Car M7604 MCL-160 M310 Slag Detection Various Cameras Pouring Stream MI-S8 MI-SR5 MI-SR12-LO MI-SR50-LO Continuous Casting M90 R1 M90 R2 MI-S5 M67H M770S MI-S140 M77S Rolling Mills M90 R1 M90 R2 MI-S5 M67H M770S MI-S140 M77S Burr Detection M M Reheat Furnace M7800 MI-GA8 MI-S8 M90H MI-GA15+ M90Q MI-N5 L0 MI-P140-LO M67 D MI-S50-LO M68 H Annealing Furnace M90Q M90H MI-GA15+ MI-GA8 MI-S8 MI-S5 MI-SR50-LO MI-S50-LO M190 H M68 M770 M78 M305 Induction Heating MI-K315K M90R1 MI-S5 MI-S12 M67Q MI-GA5 MI-GA12 M68 MI-S50-LO MI-GAR12 M770S MI-SR50-LO MI-S140 MI-GA140 M305 Heat Treating M90 Mi-S5 MI-S140 M78 MI-SR50-LO M67 H M770S MI-S50-LO M305 Sand Casting Core Mold MCL-160 MI-N5+ M90D M67 Mi-N5 MI-N510 M300 M310 Sintering Vacuum Melting M90 R2 Mi-S50-LO M190 M68H MI-SR50-LO M770S MI-S140 M90 R2 Mi-N5 M190 M77 MI-SQ5 MI-SR50-LO M67 H MI-S140 M78 M190V Forging M90 H MI-S5 M67 H M78 MI-S140 M668 H M680 H MI-MS68 H M77 M190 H M305 ph fx mikroninfo@lumasenseinc.com Specifications subject to change without notice. Mikron is a registered trademark of LumaSense Technologies. All other marks are the properties of their respective owners. All rights reserved LumaSense Technologies, Inc. Brochure_Steel Industry Rev