Ergolines Advances Technology of Electromagnetic Stirrers and Sensors for Steelmakers 

September 4, 2024 Editorial Staff Electromagnetics, News 0
To determine the best electromagnetic stirring system, it is necessary to study the liquid steel motions imposed by the stirrer. Ergolines has developed a powerful designing tool for simulating and optimizing the stirring process within various situations. The tool, internally developed by ergolines researchers, divides the designing in two phases, an electromagnetic and a fluid dynamic calculation coupled by an algorithm allowing its use within the dynamic design ambient. 

The innovative character of ergolines Lab in Trieste, Italy has again been rewarded through funding to develop new technology in electromagnetic stirring and sensing for steelmaking. The latest award came in June for a proof of concept project to create a vision system to be integrated into sensors installed in the continuous steel casting process. 

The aim is to improve the evaluation of the distribution of special powders used in steel production, which is currently dependent on human intervention and has limitations. The project involves the development of compact, integrated devices to overcome current technological limitations, improving safety, production process efficiency and the quality of the product produced. Total investment cost is €222.468 and the grant allocation is €150.000. 

Few companies could muster the expertise needed for such a project. The core business of ergolines is designing and manufacturing electromagnetic stirrers (EMS) that are exported all over the world, used in various sections of continuous casting to minimize surface and internal defects of the steel and to increase productivity. It is one of only four such manufacturers in the sector, says the company. 

With a strong orientation toward designing custom solutions, it has developed its own range of products and special control systems dedicated to the steel industry, in particular to the meltshop and the continuous casting area. The range includes sensors, electric machines and sophisticated automatic process control devices, all designed to perform in unusually challenging environments. 

Electromagnetic stirrers from ergoline are used in the continuous casting process. According to the position along the casting strand and metallurgical effects, stirrers can be classified mold, strand and final stirrers.  

Other innovative products for the steel industry have been developed during the years such as a complete family of mold level control sensors including electromagnetic models, breakout prediction systems, mold oscillation monitoring sensors and ladle-to-tundish slag carry-over sensors, and instruments. 

The use of electromagnetic sensors for mold level measurement in continuous casting of steel is a worldwide common practice. Ergoline’s ILD sensor is an inductive transducer typically used for mold level control in billet and blooms casters. 
Slab strand electromagnetic stirrers are used mainly for ferritic and silicon steels. In ferritic stainless steel casting, they refine the solidification structure and prevent surface defects after rolling as ridging and roping. In silicon steel casting for electrical steel sheets production, they are useful to enlarge the equiaxial area and refine the grain dimension.  
Ergolines has developed a new-generation portable gauss-meter instrument for measurement and complete analysis of the rotating magnetic field produced by EMS stirrers. 
From the know-how acquired during years of testing, ergolines has developed a portable and extremely sturdy instrument that measures the insulation resistance of any type and brand of stirrer — a useful tool for maintenance technicians and quality control staff who want to monitor the insulation performance curve of EMS windings. 
Reconditioning and renovation services are performed on all brands of EMS, including reconstruction and enhancement of original copper windings. 
A notable recent project was the installation in 2022 of a twin-EMS system for Emirates Steel. One of the main project goals was to minimize the impact of the intervention on the existing facilities and operations, calling for ergolines to integrate its coil design into Emirates Steel’s twin-mold technology and the existing plant features. 

For more info, see www.ergoline.it. 

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