Introduction To Industry Scenarios
The core of steel smelting is blast furnace ironmaking → converter/electric furnace steelmaking → continuous casting → rolling. The working conditions are extremely harsh: high temperature (150-200 ℃ environment, 1400-1600 ℃ medium), high pressure (2-10MPa), high dust, strong vibration, strong electromagnetic interference, gas is flammable and explosive, and there are many cooling water/slurry/oxide scales.
Typical measuring points:
Blast furnace: cooling water/hot water tank level of cooling wall, top gas pressure, hot blast furnace pressure, slag flushing water level
Converter/electric furnace: oxygen lance cooling water pressure, furnace cooling water tank level, gas recovery pressure, ladle/intermediate ladle steel water level (indirect)
Continuous casting: crystallizer cooling water pressure/level, secondary cooling water level, intermediate steel ladle water level, steel billet cooling water tank level
Hot rolling/cold rolling: emulsion tank level, hydraulic station pressure, descaling water pressure, circulating water level
Public auxiliary: Gas cabinet pressure, dust removal pipeline pressure, circulating water/sewage treatment tank liquid level, acid-base regeneration tank liquid level
Adapt to Core Products
QDY30A High Temperature Input Type Liquid Level Transmitter (150 ℃, 316L/Hastelloy, anti silt IP68、 Anti vibration)
QDY60 series large-diameter static pressure liquid level transmitter (wide range, mud/oxide resistant, long-term immersion, zero stability)
QDW90A-3051 single/double flange liquid level transmitter (200 ℃, 10MPa, viscous/slag containing medium, anti clogging, flat diaphragm)
QDKG intelligent pressure switch/transmitter (0.075 level, 200 ℃, high/micro pressure, explosion-proof Ex d II CT6, anti vibration)
GLG signal isolator/RS485 isolator (2500V isolation, common mode rejection, anti frequency converter/large motor interference, long-distance transmission)
S803/SS803 intelligent digital display instrument (IP65, stainless steel casing, high temperature/dust environment, local alarm, Modbus communication)
Product Function
QDY30A/QDY60+QDW90A-3051 liquid level class
Blast furnace cooling water tank/hot water tank liquid level: resistant to high temperature of 150 ℃, waterproof against scale/sediment, real-time monitoring of cooling water volume, linkage with water replenishment valve/pump to ensure stable cooling water volume, prevent water interruption from burning through the furnace lining, prevent water overflow and waste, and extend the service life of the blast furnace.
Slag flushing water/slag pool liquid level: anti mud/oxide scale, IP68 long-term immersion, monitoring slag water level, linking slag discharge pump, preventing slag water overflow, preventing pump dry pumping, ensuring continuous operation of slag flushing system.
Continuous casting crystallizer/secondary cooling water level: QDW90A flat membrane anti scaling, high temperature resistance, precise control of cooling water level, ensuring uniform cooling of steel billets, preventing cracks/deformations, and improving the quality of castings.
Liquid level of emulsion/hydraulic oil tank: 316L anti-corrosion, anti oil pollution, monitoring oil level, linked oil replenishment/alarm, preventing oil shortage from burning the pump, preventing leakage pollution, and ensuring the stability of rolling equipment.
QDKG intelligent pressure switch/transmitter
Blast furnace top gas/hot air pressure: 0.075 level, explosion-proof certification, temperature resistance of 200 ℃, real-time monitoring of gas pressure, participation in furnace pressure regulation, prevention of negative pressure air suction explosion, positive pressure leakage poisoning, and ensuring smooth operation of the blast furnace.
Converter oxygen lance/cooling water pipe pressure: high-pressure type (0-10MPa), anti vibration, monitoring cooling water pressure, preventing water interruption and oxygen lance burning, preventing water leakage and splashing, ensuring steelmaking safety.
Continuous casting descaling water/hydraulic station pressure: high precision, impact resistance, stable descaling pressure, ensuring the surface quality of steel billets; Monitor hydraulic pressure and prevent equipment overload/malfunction.
Gas cabinet/pipeline pressure: intrinsically safe explosion-proof, micro pressure type, monitoring gas pressure, preventing overpressure explosion, preventing negative pressure collapse, ensuring gas recovery and safe transportation.
GLG signal isolator/RS485 isolator
Strong electromagnetic interference zone (rolling mill/frequency converter/large motor): 2500V isolation, common mode rejection ratio ≥ 60dB, cutting off the ground loop, suppressing peak interference, DCS signal no drift/jump, no false interlocking, ensuring continuous rolling.
Long distance signal (blast furnace → central control/rolling line → scheduling): RS485+Modbus, signal attenuation free, packet loss rate<0.1%, real-time data upload, stable traceability.
Explosion proof zone (gas zone/furnace zone) → safety zone: intrinsically safe isolation, limiting energy, meeting explosion-proof circuit safety, preventing sparks from igniting gas.
S803/SS803 digital display instrument
On site display of furnace area/rolling line: IP65, anti dust/high temperature, high brightness LED, intuitive reading during inspection, no need to climb high/enter dangerous areas, safe and efficient.
Over limit alarm/interlock: relay output, linked sound and light alarm, emergency stop/valve closing, 1-second response, preventing accident expansion (such as water outage and overpressure).
Data upload/accumulation: Modbus communication, access to central control SCADA, energy/water consumption statistics, fault tracing, meeting MES data requirements in the steel industry.
Addressing Industry Issues
Extremely prominent safety risks
High temperature and high pressure are prone to explosion/splashing; Gas leakage poisoning/explosion; Cooling water cut through the furnace lining/oxygen lance, resulting in losses of tens of millions in a single accident.
Measurement conditions are harsh and instruments are prone to damage
High temperature, high dust, strong vibration, slag/viscous media, ordinary instruments drift/block/damage for 3-6 months, frequent shutdowns for replacement, affecting continuous production.
Strong electromagnetic interference and unstable signals
Interference from rolling mills/frequency converters/large motors, DCS jumping, false alarms, and false interlocks, leading to rolling scrap and production interruptions.
High energy/water consumption, high cost pressure
Cooling/water/gas supply is adjusted based on experience, resulting in high water/energy waste, high steel cost per ton, and squeezed profits.
Manual inspection is dangerous and inefficient
High temperature and toxicity in the furnace/gas area, high altitude/narrow space, high risk and low efficiency of manual liquid level/meter reading, and lagging data.
Direct Customer Benefits
Safety benefits (life/property preservation core)
Explosion proof+isolation: The risk of sparks in the gas area is reduced to 0, the safety accident rate is reduced by ≥ 95%, and the loss of tens of millions of accidents is avoided.
Accurate monitoring of cooling system: water cut-off/shortage warning advanced by ≥ 10 seconds, 100% reduction in furnace lining/oxygen lance accidents, and 2-3 years extension of blast furnace life.
Pressure interlock: 1 second response to overpressure/negative pressure, preventing explosions/leaks/splashes, reducing unplanned shutdowns by ≥ 90%.
Quality and Capacity Benefits
Accurate control of liquid level/pressure: The cracking/deformation rate of the casting billet is reduced by ≥ 80%, the yield rate is increased by 1% -2%, and the annual production of high-quality steel is increased by ≥ 5000 tons.
Signal stability: DCS misoperation is reduced by ≥ 98%, scrap rate is reduced by ≥ 70%, and annual scrap losses are reduced by ≥ 3 million yuan.
Continuous operation: instrument failure rate reduced by ≥ 80%, annual effective production time increased by ≥ 20 days, and production capacity increased by ≥ 5%.
Energy saving and consumption reducing benefits (direct savings)
Accurate regulation of cooling/water supply: Reduce water consumption per ton of steel by 10% -15%, save water of at least 500000 m ³ per year in a million ton steel plant, and save water costs of at least 400000 yuan.
Stable gas recovery: The gas recovery rate has increased by ≥ 3%, and the annual value of recovered gas is ≥ 2 million yuan.
Pump/fan frequency conversion linkage: reduces power consumption by 8% -12%, saves energy of at least 800000 kWh per year in a million ton steel plant, and saves electricity costs of at least 640000 yuan.
Maintenance and labor benefits
High reliability design: The instrument has a lifespan of 2-3 years, with an annual maintenance cost reduction of ≥ 70% and a reduction in spare parts/labor expenses of ≥ 500000 yuan.
Unmanned operation: Reduce manual inspections by ≥ 80%, save labor costs of ≥ 150000 yuan per year, and eliminate risks of high-altitude/toxic operations.
Management and compliance benefits
Accurate and traceable data: meeting the MES/ISO system requirements of the steel industry, data is authentic and cannot be tampered with, improving the level of management refinement.
Intelligent upgrade: connected to the smart steel plant platform, remote monitoring/scheduling, management efficiency improved by ≥ 60%, in line with the national steel intelligent manufacturing policy.
