Digital twin model of a large scale hot molten metal ladle pouring system

Abstract In steel-making processes, large quantities (frequently exceeding 300 t) of liquid metal are transferred between vessels. In Basic Oxygen Steel (BOS) making process, metal is poured from Hot Metal (HM) ladles, utilising overhead gantry cranes, into furnaces for further processing. Due to the large quantities of liquid metal poured, this operation poses significant safety concerns associated with metal spillage and releases of heat emissions. This can further lead to damage being caused to surrounding infrastructure. Pouring automation can reduce the likelihood of metal spillage, optimising ladle movement for reduction in heat emission releases. Given the hazardous nature of this operation, robust testing and evaluation of automated crane pouring movements is required prior to their application. 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 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 rigid joint frictional components. The flow rate of HM is estimated through the application of a dynamic model, allowing the modelling of system dynamics due to differences in HM pouring weights. The devised DT model is evaluated by simulating real crane movement and making a comparison on the resultant changing HM weight inside the ladle. The devised DT removes the need for construction of a physical model or performing tests directly on the HM pouring system.