Product officer for metals monitoring instruments.

Sensmet Oy has announced the appointment of Jyri Hämäläinen as Chief Product Officer (CPO), a lead role in which he will spearhead the development of the company’s unique continuous metals monitoring instruments.

Jyri Hämäläinen 

Jyri brings over 25 years of cross-functional executive leadership spanning technology, product development, global sales, and marketing. Most recently, as Co-Founder and Director at Emberion, he defined product strategies and led global sales and marketing, taking a photonics deep-tech startup from early incubation to exit. His career also includes key director roles at Nokia Technologies driving sales development and commercial partnerships, alongside strong operational roots in heavy industry and strategic consulting at Boston Consulting Group.

“I am very pleased to be joining Sensmet at this pivotal stage in the company’s growth,” explains Hämäläinen. “Sensmet’s core technology is extremely impressive, and has been proven in a wide variety of applications. By delivering a solution to the continuous measurement of metal concentrations, Sensmet has resolved a major challenge for many rapidly growing industries, so I am excited to take on a role that will help to leverage that technology, and make it applicable to a much wider group of customers and applications.”

Sensmet CEO, Dr Toni Laurila says: “We are delighted to welcome Jyri to the Sensmet team. He is a highly accomplished individual with impressive credentials, and I am sure that he will play an important role in accelerating Sensmet’s growth.”

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@Sensmet_Ltd @_Enviro_News #PAuto 

Major European investment for metals monitoring.

Sensmet, the Finnish developer of a unique continuous metals monitoring technology, has received a major investment (€1.5m) from EIT RawMaterials which is supported by the European Institute of Innovation and Technology (EIT), a body of the European Union, to help secure the supply of critical and strategically important raw materials.

Sensmet will use the funds to leverage the scale-up and deployment of its µDOES® online metals analysers to strengthen Europe’s raw materials resilience and competitiveness. 

“Our highly innovative technology provides process managers with continuous measurements for key metals within liquid process streams,” explains Sensmet CEO, Dr Toni Laurila (right). “This enables them, for example, to extract critically important metals much more efficiently than would have been previously possible when relying on laboratory analysis.”

This technology is deployed in numerous applications within raw material value chains – including wastewater treatment, battery recycling, lithium production and fertilizer manufacture. Sensmet has been chosen for this investment because continuous measurements in these applications enable and enhance the recovery of metals that are critically important for the digital economy.

EIT RawMaterials’ mission is to secure a sustainable, independent supply of materials for Europe. EIT RawMaterials is a Knowledge and Innovation Community cofunded by the European Commission and one of Europe’s most active innovation ecosystems in the raw materials sector. The organisation supports technologies and industrial solutions that strengthen Europe’s security of supply for critical raw materials such as lithium, cobalt, nickel, and rare earth elements (REEs), which are essential for batteries, renewable energy systems, and advanced manufacturing.

“Our business aligns perfectly with the goals of EIT RawMaterials,” adds Toni Laurila, “so we are honoured to receive this investment, and excited to see how we can use it to scale the µDOES platform and accelerate growth.”

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@Sensmet_Ltd @EITeu @_Enviro_News #PAuto #Europe

Virtual process line visualisation.

A tool for experts- and those who want to become one.

EMG is renowned for its expertise in flat materials production and processing, especially steel and aluminum. Whether in the hot or cold section, on coating, annealing, galvanizing or tinning lines - their systems have become an integral part of ensuring quality, stability, and process control in demanding production environments. The portfolio includes sensor systems, strip guiding elements, hydraulic solutions, actuators, and comprehensive quality assurance systems.

But as the breadth and complexity of EMG’s product landscape has grown, so has the challenge: How can potential customers or partners quickly grasp where and how these solutions fit into their specific process lines? With well over 100 possible installation locations across various line types and process sections, it’s easy to lose the overview.

To address this challenge, EMG has launched a digital process line visualisation tool on its website - a highly intuitive and interactive resource for anyone seeking clarity, insight, and product information.

Navigating process lines digitally.
The new online visualisation starts with a macro-level view: the user selects a specific line type, such as a continuous galvanizing line, continuous coating line, or cold rolling mill. With a single click, the viewer zooms into a detailed digital representation of the line layout, clearly showing where individual EMG systems are typically installed.

Each possible installation location is marked and clickable. Whether it’s a sensor measuring strip width after the uncoiler, or a strip guiding system at the strip accumulator - every element is anchored within its real context.

This structure reflects the real-world complexity of these lines while offering a streamlined path to the relevant information. By focusing on each line section, users not only understand where a product is installed, but also why it's needed and how it contributes to the process.

Deeper insights at every level.
What truly sets EMG’s visualisation apart is its layered depth. After selecting an installation point, users are taken to the products used at that position. Each product is presented with a high-resolution, rotatable 3D model, offering a realistic impression of the system’s form and look.

From there, technical specifications, typical application scenarios, customer benefits, product brochures, and direct links to EMG’s product website are only one click away. As an example, users examining the strip width measurement after the uncoiler can compare solutions such as the EMG BREIMO or EMG iCAM®, and view both hardware and feature highlights instantly.

The system also offers a seamless connection to EMG’s service infrastructure. On every process line overview, users can access relevant links to service offerings including repairs, spare parts, retrofits, and maintenance. This makes the tool not only useful for engineering and quality management but also highly relevant for service teams and plant operators.

A tool for experts- and those who want to become one.
With this new digital platform, EMG combines its decades of experience with modern visualisation technology to provide a unique user experience. The tool is especially valuable for production engineers, maintenance personnel, and quality management professionals looking for fast, reliable insights into how EMG solutions can fit into their specific process environments.

Whether you’re exploring new equipment for a plant upgrade, planning a retrofit, or simply comparing technologies - this tool enables you to dive as deep as you like. From high-level line overviews down to interactive 3D product visualisations, the structure offers both orientation and detail, tailored to your needs.

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@PresseBox #EMG #PAuto 

Temperature measurement solutions in metal mining and processing.

Advanced solutions for metal ore extraction

AMETEK Land provides advanced solutions to meet the intricate demands of ore extraction applications. Precise furnace temperature measurements using instruments such as AMETEK Land’s thermal imagers are essential to support safety, effective process efficiency and superior product quality in platinum and nickel ore extraction.

Non-contact infra-red thermal imagers provide critical temperature data which is used to produce consistent, high-quality products and inspect the condition and integrity of high-value assets, without putting operators at risk.

Madeleine Lake, Global Industry Manager - Energy & Minerals, said: “Metal ore extraction requires advanced process control and precise furnace temperature measurements for a superior end product. Our accurate, non-contact solutions deliver this and more, including emissions and safety monitoring in the mineral plant.”

For a continuous and clear view through heavy smoke and hot furnace atmospheres, the MWIR-Borescope-640 is a highly accurate radiometric infrared imaging camera with spectral filtering for continuous temperature measurement and furnace profiling applications. 

The NIR-Borescope-656 is a high-resolution short wavelength full radiometric infrared borescope imaging camera designed to produce continuous live high-definition thermal images. Measuring temperatures in the range of 600-1800C, it is suitable for a wide range of continuous process monitoring and control applications, providing high-resolution images and temperature readings in large furnaces.

Benefits of using the NIR-B-656 include optimised furnace temperatures leading to energy savings, increased efficiency and reduced emissions.

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@landinst @codacomms #PAuto #Mining

Supporting metal quality and reducing costs.

LADA Foundry is focused on delivering top-quality products from its SG/ductile iron plant, which requires accurate measurements of the liquid metal during the casting process. Traditionally the foundry used dip thermocouple tips in combination with a pyrometer which takes longer and increases operator risk and cost. AMETEK Land’s Cyclops 055L portable pyrometer can address all these issues.

Capable of taking a non-contact measurement in under two seconds, the Cyclops improves operator safety with its point-and-shoot function, allowing the operator to be positioned several metres away from the molten metal.

It also significantly reduces the use and cost of disposable dip-type thermometers and improves measurement accuracy with its clear, wide-angle field of view and clearly defined measurement area for precision sighting.

After implementing the Cyclops into its process, LADA Foundry stopped using thermocouple tips completely, resulting in a cost savings of approximately INR 7,000,000.

LADA Foundry Plant Head, Mr. Yuvraj Patil, said: “The Cyclops 055L provides us with a safe, accurate and fast temperature measurement, and is helping us to improve production at our facility. Because the Cyclops is portable, we can measure each mould pouring temperature, and at the furnace, which helps to avoid super-heating.”

Its rugged instrument casing means the Cyclops 055L is used by foundry operators worldwide and in a wide range of applications including melting furnaces, ladle treatment locations, pouring sectors, blast furnace runners and liquid metal transfers. 

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@landinst @codacomms #PAuto #Steel #India

Real-time measurements in a metals refinery.

Sensmet's continuous metals monitoring technology has been evaluated in a field trial conducted by Metso at its facilities in Pori, Finland. The trial compared Lithium and Sodium measurements by laboratory ICP-OES analysis with the Sensmet µDOES® continuous analyzer, and demonstrated excellent correlation between the two different methods.

Traditionally, hydrometallurgical production processes have relied heavily on regular sampling and laboratory analysis for process control. However, as Sensmet CEO, Dr Toni Laurila explains: "Lab analysis is costly and incurs a significant delay, which means that real-time control of such processes has not hitherto been possible. Importantly, this trial was conducted under field process conditions, and has confirmed the widely held view that our µDOES® continuous metals analyser represents an enormous opportunity for the optimization of lithium production processes."

Comparing µDOES® with lab ICP-OES.
During the trial, samples were taken from a process in which battery-grade lithium hydroxide monohydrate was produced from spodumene concentrate treated by high-temperature conversion in a rotary kiln. The hydrometallurgical technology, developed by Metso, produces battery-grade lithium hydroxide monohydrate by soda pressure leaching. In this application, the analytical performance of the µDOES® analyser was evaluated for the continuous optimization of pressure leaching and conversion leaching.

Over sixty samples were drawn from the process and analysed by a µDOES® continuous analyser and a laboratory ICP-OES. Sodium and lithium concentrations were measured in each sample, and the results showed an excellent degree of correlation between the online instrument and laboratory reference analysis. The calculated R² (coefficient of determination) for the two elements were 0.98 for the lithium comparison and 0.95 for sodium.

"We were impressed by the outcomes of the measurement campaign, conducted in a challenging environment replicating real-life conditions. Despite the rigor, the µDOES® and ICP-OES delivered congruent results," explains Metso's Veli-Matti Järvinen, Vice President – Automation Product Group. "This is significant — we anticipate that the µDOES technology will bring substantial value to the realms of battery metal production and recycling processes when integrated to Metso Courier® HX system."

µDOES® inside.
Metso is a global frontrunner in minerals processing and metals refining, possessing expertise covering the extraction of lithium from brines and pegmatite ores up to battery-grade lithium salts. When it comes to adopting analytical technologies into production processes and automated measurement systems, Metso upholds the most stringent standards for technology reliability.

The Metso evaluation confirmed the exceptional performance and great potential of µDOES® to transform the way Li and Na analyses are conducted in brines. Following the trial, Metso will adopt µDOES® technology in selected Courier® HX systems for Li and Na analysis, and the new systems will be available globally in 2024.

Explaining the importance of the Metso trial, Sensmet CEO, Dr Toni Laurila says: "Previously, we have demonstrated the advantages of µDOES® in battery metal analysis; delivering increased efficiency, lower costs, and improved product quality. However, one of the first questions that every customer asks is: do we have comparison data with laboratory ICP-OES from real processes?

"We are therefore delighted that an industry leader like Metso has performed such a verification and shared these exciting results. The Li and Na comparisons with ICP-OES illustrate the high analytical performance of the µDOES® and the tremendous potential of real-time analysis in brines."

Sensmet's patented µDOES® technology is based on atomic emission spectroscopy. A micro-discharge (electric spark) is created directly inside the aqueous sample, causing a microscopic volume of the fluid surrounding the spark to be flash-heated to 10 000 °C. Molecular species in the micro-discharge are dissociated into atoms, which are excited to their respective higher electronic states. Upon returning to their ground state, these atoms release their excess energy by emitting light at their characteristic wavelengths. The µDOES® measures this atomic emission spectrum to derive quantitative analysis of the metals contained in the sample.

µDOES® is able to continually repeat these measurements 24/7 delivering results with a user-selectable measurement interval of 5 - 30 minutes.

Summarising, Sensmet CEO Toni Laurila commented: "The third-party evaluation shows how µDOES® technology allows operators to consistently produce high-quality, continuous 24/7 measurements, akin to results obtained in a laboratory. This capability is accessible directly at the process plant, avoiding the delays of lab analyses, and exploiting the benefits of real-time process monitoring."

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@Sensmet_Ltd @_Enviro_News #PAuto

Induction heating.

Induction heat treatment is a highly versatile technique widely used to alter the mechanical properties of materials including metals and alloys. However, accurate temperature control is crucial to achieve the desired temperature and material properties, and to control both the heating process and induction generator.

AMETEK Land supports industries including manufacturing, automotive, aerospace and construction with highly accurate and reliable temperature measurement solutions for induction and heat treating applications. The company offers a wide range of dedicated pyrometers, line scanners and thermal imagers to optimise these heating and processing applications*.

Manfred Hayk, Global Infrared (IR) Product Manager - Product and Application Support said: “It can be challenging to obtain accurate temperature measurements in industrial processes. Our wide range of dedicated solutions are chosen by customers around the globe because of our proven technology and infrared temperature measurement experience, helping to provide controlled and precise measurements while optimizing process efficiency and increasing product quality.”

One key solution is the SPOT+ range of pyrometers. These smart infrared pyrometers offer advanced industrial connectivity and visible light process video, making non-contact temperature measurements accurate and flexible, especially in the harshest of environmental conditions.

Thermal imaging cameras and systems also play an important role in industrial processing and furnace applications, forming a crucial component for visualising, controlling, and documenting the induction heating and heat treatment process.

LAND’s advanced cameras and systems, including the MWIR-640 and LWIR-640 imagers, and the NIR-2K, working with the IMAGEPro advanced processing and control software, help to meet the increasing demand for improved product quality, process efficiency, energy saving, predictive maintenance and emissions reduction.

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*See their Application Note: "TEMPERATURE MEASUREMENTS FOR INDUCTION HEATING AND HEAT TREATMENT PROCESSES ." 

 

@landinst @codacomms #PAuto #Metals

Call for action to accelerate global sustainability

Real Progress campaign begins with automation, electrification and digitalization in mining, metals and pulp and paper industries

ABB has launched a new global sustainability initiative, showcasing the power of technology and expertise to accelerate sustainability while enhancing productivity has been launched by ABB. Their Real Progress campaign is a rallying call to customers, partners and suppliers, inspiring them to harness technology leadership and the solutions that exist today to amplify their own impact across process industries such as mining, metals and pulp and paper.

For more than 130 years, the technology leader has been embedded in industries where emissions are hard to abate and where alternative solutions are either unavailable or difficult to practically implement. Today, ABB is combatting many changes happening in the world, such as rising emissions, water and energy scarcity and workforce skills challenges. The company is showing that the power of bold ideas and pioneering technologies can overcome these challenges, step by step, together with the wider industrial and societal ecosystem.

The decarbonization challenge unites the mining, metals and pulp and paper industries with leadership teams striving to meet increasing market demand with a more rapid increase in energy and resource efficiency to reach their committed sustainability targets such as more carbon-neutral operations. Across these vital process industries, there is a growing recognition that automation, electrification and digitalization are essential components of their journey towards meeting climate targets set out by businesses, legislation, governments and international agreements over the next 25 years and beyond.

“The journey toward sustainability isn't a gradual progression; it's a bold transformation. The actions and decisions we take today, together with every innovation we embrace, are powerful steps towards a sustainable future, and we're unapologetically leading the charge,” said Joachim Braun, Division President, ABB Process Industries. “Every day, ABB is working side by side with customers in their mines, their mills and their plants, to provide complete technology solutions with automation, electrification and digitalization to radically reduce emissions and energy use. Together with our great network of partners, we are proud of driving real progress in sustainability, but we know that more can and must be done. We’re part of the journey and commit to making real progress always.”

In the metals industries, ABB is committed to enabling customers to use less energy and raw materials when producing steel and aluminum through advanced automation and electrification systems, combined with industry-specific equipment and digitalization, across plants. One solution that brings autonomous plants to life is ABB Ability™ Smart Melt Shop. It facilitates operational excellence by combining real-time crane and ladle tracking, automatic and optimized crane scheduling and heat loss prediction. Benefits include raising casting speeds by 4-5 percent, 5 degrees Celcius less arcing per heat, reduced delays, less material rejection and increased human safety​.

As steel companies move from traditional blast furnace-basic oxygen furnace (BF-BOF) to more sustainable electric arc furnace (EAF) steelmaking, technologies such as ABB’s ArcSave® electromagnetic stirrer (EMS) can also be deployed in the melt shop to create equilibrium in the melt, enabling more steel to be made, faster and using fewer resources. In partnership with Tenova, this solution has been deployed on the world’s largest EAF, operated by customer Acciaieria Arvedi in Italy. The results include an 18 degrees Celcius lower tapping temperature, a 3.6 percent reduction in electrical energy consumption and a 38,000-ton annual reduction in CO₂e emissions at the plant. EAF productivity has also increased by 5 percent.

ABB Ability™ Energy Management System is a digital solution that provides monitoring and optimization of energy consumption and CO₂e footprint across the metals enterprise. Benefits of this solution include improved planning of operations and 5 to 15 percent energy cost savings in the entire plant.

Electrification is a key pathway to more sustainable metals manufacturing. Leveraging 100 years of metals process know how, ABB experts work together with customers to tailor drives and motors solutions to perform reliably and precisely according to the demands of each process. From primary steelmaking through rolling and processing, using ABB medium and low voltage drives and motors means more efficient energy use, cutting operating costs.

“Alongside some of the foremost steelmakers and aluminium producers in the world, we’re facing a reality that the industries consume large amounts of energy and are responsible for a large proportion of CO₂e and greenhouse gas emissions today,” said Frederik Esterhuizen, Global Business Line Manager, Metals, ABB Process Industries. “We’re enabling mills to take control of their processes and equipment to improve process efficiency, product quality and yield while maximizing resource and energy efficiency. In this way, we will help to limit climate change and create real progress for future generations.”

“Sustainability isn't an option; it’s an imperative for every business leader in our rapidly evolving world. To thrive and create a better future, we must embrace sustainability at the core of our operations,” said Rohit Sharma, Global HSE and Sustainability Manager, ABB Process Industries. “It’s not only about being responsible but also about staying competitive and resilient in an ever-changing global landscape. Our commitment to sustainability today will define our success and impact generations to come.”

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@ABBgroupnews @abbindustryserv @abb_automation #Steel #Pauto

Aluminium temperature.

AMETEK Land has designed its integrated thermometer systems specifically for the temperature measurement of aluminum.

The new SPOT+ AL is an advanced infrared digital pyrometer, providing an all-in-one temperature measurement for aluminum. Covering a wide range of different temperature measurements, the SPOT+ AL pyrometer is a single product that can be used in every part of the aluminum production process including extrusion, quench, strip, forging and liquid aluminum applications.

Now available with Ethernet IP connectivity, the SPOT+ AL will enable plant operators to reduce costs, enhance integration and lower training requirements as separate instruments are not required across the plant.

Larry Smith, Director of Sales - Americas, said: “We provide established and time-proven systems that are used in aluminum plants worldwide. These products meet the highest standards of quality and reliability, to ensure accurate performance under plant operating conditions.”

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@landinst  #PAuto

Futureproofing a mill.

Retrofit will improve availability, reliability, energy efficiency, and productivity, while cutting downtime and maintenance

The leading sustainable aluminum solutions provider and the world leader in aluminum rolling and recycling, Novelis Inc., is working with ABB to upgrade its third-party drives and controls system as part of a brownfield modernization project at its hot rolling mill in Oswego (NY USA).

To futureproof the mill, ABB is replacing obsolete and outdated equipment with new switchgears, transformers, medium voltage drives, medium voltage synchronous motors, motor control centers and auxiliary controls, all integrated with the facility’s existing non-ABB control system. This will support Novelis’ ambitions for increased power capacity and reliability. Commissioning of the upgrade is expected by the end of 2023.

The Oswego mill was the company’s first US operation and is today the company’s largest, wholly owned fabrication facility in North America. It produces high-quality aluminum sheet for the automotive, beverage can, and building and construction markets. Novelis is also the world’s largest recycler of aluminum and seeks sustainability commitments from its supply chain as its customers look for environmentally friendly and circular aluminum products.

“In order to continue to provide our customers with the highest quality, sustainable aluminum sheet, and do so reliably, we are focused on increasingly optimizing our production output,” said Ganesh Panneer, Vice President of Operations, Novelis North America. “ABB is helping to ensure that we continue to have the highest levels of availability in our processes. The expertise of the ABB metals team, together with their commitments on providing the latest, most energy efficient products, will secure Oswego’s future as we maintain our leading position.”

“We’re proud to support Novelis in meeting their production targets, which promote efficient use of energy and other resources,” said Siraj Boudighar, Sales Manager North America for Metals, Process Industries, ABB. “By leveraging our long-term experience and in-depth knowledge of metals industry processes, including more than 400 references for modernization projects since the year 2000, we are able to tailor technology packages that meet the specific needs of each customer.”

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@ABBgroupnews @ABBMeasurement @abb_automation @AdmiralPR @Novelis #PAuto

The start of digital transformation!

The technology that revolutionized gas analysis and emissions monitoring in chemical plants and refineries, the pulp, paper and metal industries, power generation, cement, and others.

URAS was created by German engineers Erwin Lehrer and Karl Friedrich Luft. In 1988, the technology was further improved by adding gas-filled calibration cells. Because it no longer needed high-pressure test gas cylinders, the cost of operation dropped significantly and increased the ease of use.

When launched 85 years ago, 1938, URAS was known as the first “ultra red absorption recorder” (in German, Ultra Rot Absorptions Schreiber), a continuous gas analyzer capable of instantly measuring the concentration of more than 100 gases through infrared spectroscopy (light absorption technology).

“This technology was truly revolutionary from the day it was invented. Today, it is a benchmark for uncompromising environmental compliance. With URAS, numerous industrial companies around the world are able to monitor emissions and safeguard the environment,” said Ben Goossens, ABB Measurement & Analytics.

URAS is used by industrial companies around the world as a key solution for ensuring environmental compliance. With its unrivaled monitoring uptime, this technology is used in the continuous monitoring of gases that come out of industrial chimneys. It also measures emissions from marine vessels, helping shipping companies comply with environmental regulations.

As a continuous gas analyzer, URAS has a wide range of applications beyond the industrial segments – from helping save lives in hospitals by measuring the CO2 levels in diagnostic breath tests to supporting the process of ripening of bananas during shipment by analyzing the concentration of ethylene.

In 1996, URAS was used as a foundation in ABB’s groundbreaking Advance Optima modular analyzer, which unified the operation for all types of gas analyzers in one single design. With this, URAS became the first network analyzer with its own IP address. This was the beginning of the digitalization of analyzer technology.

“Decades before the Internet of Things, URAS communicated digitally. Today, it’s all about the digital transformation and this is where it all started,” said Ben Goossens.

@ABBgroupnews @ABBMeasurement @abb_automation #PAuto #Gas

Digital and control system for steel mill.

Helping steel producer in France to bring productivity to a new level, improve quality and performance.

ArcelorMittal Construction has awarded ABB a contract to deploy solutions specifically designed for metals processing at its cold rolling mill in Contrisson (F), as part of a modernization project. The solutions, which include ABB Ability™ Manufacturing Operations Management for metals (MOM4Metals), Roll-Gap (RGC) and Automatic Gauge Control (AGC), will help the world’s largest steel producer to bring productivity to a new level, improve quality and performance.

ABB MOM4Metals product, based on precise data analytics, improves information sharing, production planning, execution, reporting, asset monitoring and operational performance optimization. It is designed for and used in various metal production processes from rolling mills to processing lines delivering clear benefits over generic industry-agnostic MES platforms.

ABB is also modernizing advanced RGC and AGC technologies to reduce thickness deviations and off-gauge length. The project is expected be completed in the first quarter of 2024.

“ArcelorMittal Construction has placed its trust in ABB know-how and solutions for cold mill applications,” said Frederik Esterhuizen, Global Business Line Manager for Metals at ABB. “Through discussions with the customer we have been able to utilize our deep metals expertise to refine the ABB solution to meet their needs. ABB solutions enable cold rolling mills to improve and maintain performance and meet quality requirements in terms of thickness tolerances, flatness and surface characteristics via precise process control and equipment lifecycle management.”

“ABB will bring a combined MOM4Metals and RGC/AGC automation solution specific to metals processing to our modernization project at Contrisson,” said Frédéric Geoffroy in charge of process and automation department at ArcelorMittal Construction. “This stands out from standard automation and digital solutions and we are pleased that our needs can be met by one supplier with whom we have a long standing relationship at and beyond this site. ABB successfully revamped the drive of the cold rolling mill previously.”

“For ArcelorMittal Construction France, leader in the field of steel building envelopes, ABB supports us through its business solutions and allows us to offer our customers innovative solutions based on decarbonized and sustainable steel.”

Technology is a decisive factor in determining the quality of rolled products. ABB’s rolling mill solutions, including metals specific electrical, process automation and control technologies, leverage over 100 years of metals industry expertise to enable increased speed, reduced non-rolling time and threading problems while allowing for precise process control in terms of strip surface, flatness, thickness, off-gauge length and more to deliver improved strip quality, productivity and resource efficiency.

@abbcontroltech @ABBgroupnews #PAuto #Metal #France

Pyrometer for liquid steel & metal.

Liquid steel and metal foundry and tapping operators can now benefit from improved and smart temperature measurements for process control and product quality improvements with the new smart SPOT Meltmaster (MM) application pyrometer from Ametek Land. It offers a single-sensor solution for liquid metal temperature measurements in foundry and tapping applications.

This smart application pyrometer accurately measures tapping stream and liquid steel and metal temperatures independent of surface and condition changes during the process. This is done through optimised signal processing and a dedicated application mode, by just choosing the application mode of Plug’n’Play.

It also has millisecond responsivity with advanced time functions to monitor and hold the tapping temperature for a configured time, or until the next tapping process starts.

Multiple digital and analogue interfaces enable easy integration into both new and existing process control systems or a fully autonomous operation. These include the Ametek Land Jumbo Display, which can be used with the SPOT MM to monitor the tapping temperature via the 4-20mA output of the pyrometer.

The SPOT MM also incorporates an internal visual camera to aid alignment and provides a remote process view via the integrated webserver of the pyrometer. The webserver and industrial ethernet interface (Modbus TCP/IP) enable full remote access to the SPOT MM without any additional software requirements.

Compatible with the SPOT Actuator for alignment and tracking of tapping streams, the SPOT MM can also be used with a range of accessories, including the industrial enclosure with cooling and air purging options. This allows the SPOT MM to work in harsh, extreme, environmental conditions.

@landinst  #PAuto #LiquidMetal

Temperature measurement in metal product manufacture.

AMETEK Land has supported a major metal products manufacturer to significantly reduce its costs. Based in Faridabad, Haryana, India, Amar Udyog is a leading manufacturer of grey iron, ductile iron, and SiMO machined castings, and has become a highly reputed OEM supplier for many popular brands.

The company operates a sophisticated manufacturing unit with a production capacity of 18,000 tons per annum, using cutting-edge technology to manufacture components for industries including the agricultural and automotive sectors.

Product quality is essential to meet customer requirements and specifications, and this is dependent on reliable, accurate temperature measurements at the foundry stage.

To achieve these measurements, Amar Udyog had been using dip thermocouples, which have a 13-14-second measurement time and require an operator to get quite close to the process*. The disposable thermocouple tips must be replaced frequently, costing time and money.

He was looking to reduce its high costs for maintenance, calibration, and monthly consumables, which included a typical monthly spend of INR 95,000 on replacement thermocouple tips.

To solve this challenge, AMETEK Land supplied two of its Cyclops 055L 2F portable pyrometers for this application. This device takes a non-contact measurement in under two seconds and is ergonomically designed for single-handed use.

The Cyclops 055L 2F also increases safety, as the operator can be positioned five or six metres away from the molten metal. They simply point the Cyclops 055L 2F at the liquid, then pull the trigger when a measurement is required.

AMETEK Land also provides NABL calibration and service support for the Cyclops 055L 2F in India, so Amar Udyog can access rapid local assistance if required.

Puneet Vinayak, Director at Amar Udyog, said: “Using the Cyclops 055L 2F has significantly reduced the amount we spend on thermocouple tip replacements each month. The instruments are easy to use, provide fast, accurate measurements, and increased safety for the user. We would definitely recommend AMETEK Land, both for their liquid metal measurement solution and for the expert support they have provided.”

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* The Amar Udyog case study.

@landinst  #PAuto #LiquidMetal #India

Metals and mining software.

AspenTech, an Emerson majority-owned subsidiary, has entered into an agreement to acquire Micromine, an end-to-end mining software provider. This acquisition will build on AspenTech’s leading software portfolio, furthering its diversification strategy into the metals and mining market and facilitating the digital transformation and sustainability goals of the industry.

The transaction with AspenTech, which closed in May 2022, accelerates Emerson’s software strategy and demonstrates commitment to build a higher growth, more diversified and cohesive portfolio. This proposed acquisition of Micromine is an example of how Emerson and AspenTech will drive growth through continued investment and M&A.

Micromine, headquartered in Perth, Australia, offers solutions relevant to every step of the mining process from exploration, evaluation, design and planning through production and optimisation. Micromine’s solutions are used at over 2,000 sites across all major mining regions.

Following AspenTech’s completion of the proposed acquisition, Emerson will continue to be a 55% shareholder in AspenTech.

@AspenTech @Emerson_News @EmersonExchange @EMR_Automation @MICROMINE #PAuto 

Metal quality and casting safety.

AMETEK Land has supported a major India-based manufacturer in its metal quality and casting safety goals.

DN Castech, an engineering components manufacturer operating in Gujarat, works with many major global brands and must ensure a high-quality product through accurate measurements of the liquid metal during the casting process.

The company had been using dip thermocouples for this application. However, these have a long measurement time, require operators to get quite close to the hot process, and use disposable tips.

Experiencing high costs for maintenance, calibration, and monthly consumables, DN Castech wanted to find a more cost-effective solution that would also improve both measurement accuracy and user safety.

The company turned to AMETEK Land’s Cyclops 055L portable pyrometer, which provides highly accurate measurements of liquid metal temperatures in the range of 1,000 to 2,000 °C (1,832 to 3,632 °F), with high repeatability. The Cyclops 055L takes a fast non-contact measurement within two seconds and is ergonomically designed for single-handed use. It increases safety as the operator can be positioned 5 or 6 metres away from the molten metal, simply pointing the device and pulling the trigger when they wish to take a measurement.

AMETEK Land also supplied its Model RPI 10000 BT LED display unit, which connects wirelessly with the Cyclops 055L using Bluetooth to provide instant, real-time temperature measurement updates on its 4-inch-high, seven-segment screen. With a 50-metre connectivity range, the LED display unit allows the pyrometer to be used easily throughout the foundry to validate temperature data for quality and process control, without the safety hazards that cable connections could cause.

Before the Cyclops 055L was introduced, DN Castech was spending around 540,000 rupees a year on dip thermocouples, using 30 thermocouple tips per day. Since the Cyclops 055L has no consumables and eliminates the time spent replacing tips, it offered a rapid return on investment.

It also met DN Castech’s requirements for a more accurate and safer liquid metal temperature measurement solution.

Shri Dhirubhai Patel, Managing Director at DN Castech, said: “The Cyclops 055L has been easy to use and provides a fast measurement. It is highly accurate, even while pouring, right up to the last mould. Its performance and excellent return on our investment mean we would certainly recommend AMETEK Land for this application.”

@landinst @codacomms #Pauto #India

Pyrometers for mono, ratio, and application measurement of metals.

AMETEK Land offers one of the widest ranges of single-spot pyrometer types for mono, ratio, and application measurement of metals. 

Application Note

Mono (or monochromatic) pyrometers operate on a single wavelength, which relies on a clear view of the product and knowing the emissivity of the surface to obtain an accurate temperature measurement. Ratio pyrometers operate at two separate wavelengths, correcting for dust, dirty windows, and obstacles in the optical path. This is also true for unknown or slightly changing emissivity, providing both wavelength channels are affected proportionally by temperature or process changes.

Emissivity can vary with temperature, measurement, wavelength, or surface conditions. Dirt and dust in the process atmosphere will obscure the view of a pyrometer, reducing the amount of radiation collected. Specific process and environmental conditions must be considered when selecting the correct spectral range, which is why AMETEK Land’s range provides accurate pyrometers according to the optimum wavelength for the measuring instrument.

With proven, reliable electronics, the SPOT Series has a precision optical system that delivers accurate, repeatable temperature measurements. It also features an integrated visible camera, light fibre optic instruments, and an integrated webserver.

The SPOT Ratio (R-Series) offers different operating modes, selectable from the set-up menu, including “Mono,” “Duo,” “Ratio,” and “Multi.” The R100 F.O. and R160 F.O. are also available as light fibre instruments for use in narrow spaces, locations of high temperatures, or with strong electromagnetic field applications.

There are several application pyrometer models available, such as the GS and the AL. The GS is a smart advanced pyrometer combining SPOT technology with specialised software algorithms, specifically designed for continuous, highly accurate measurement of coated steel strip temperature during galvanising and galvannealing and silicon/electrical steel.

The SPOT AL is a highly accurate and smart application pyrometer using cutting-edge SPOT technology and unique, advanced data-processing algorithms to measure aluminium temperature in the aluminium processing industry, including profile extrusion processes, quenching, heating, forming/forging applications, and for liquid aluminium or aluminium tapping.

Manfred Hayk, Global Infrared (IR) Product Manager, of AMETEK Land, said: “Our range of highly accurate and stable and smart digital pyrometers uses cutting-edge SPOT technology to provide the accuracy required for mono, ratio, and application measurements to give you dependable results.”

@landinst @codacomms #PAuto #Metal

Melt shop productivity, savings & safety enhanced.

ABB has launched ABB Ability™ Smart Melt Shop, the first smart factory digital application of its kind for the metals industry. It is designed to increase melt shop productivity, save energy and improve employee safety, with payback within six months.

Benefits include: Productivity • 4-5 percent increased casting speed due to better superheat compliance • Reduced tapping delays, in EAF or converter due to more efficient scheduling of cranes for ladle movement • Better ladle management and maintenance planning thanks to access to historical data on all movements • Increased manpower productivity since no manual intervention or acknowledgement is required Energy efficiency • 5 degrees Celsius less arcing per heat (batch) in ladle furnace using thermal models to accurately predict target lift temperature • Improved decision-making thanks to forecasting of ladle movements and crane schedules Safety • Increased safety with less footfall in hot zones which would otherwise be needed to manage ladle and crane movement

Based on advanced digital algorithms, the new solution is unique in that it offers not only powerful real-time ladle tracking but also automated crane scheduling and a predictive thermal modelling engine. The tracking engine follows ladle movement via cranes and transfer cars in real time. Radar and laser positioning technologies provide accurate visualization while reducing hardware footprint and maintenance needs compared to radio-frequency identification (RFID) solutions. The automated crane scheduling includes job forecasting, route planning and automatic acknowledgement of jobs.

This will enable steelmakers to move towards autonomous operations by eliminating manual co-ordinations, with increased safety in hot zones due to lower footfall.

The thermal engine function uses ladle thermal history from the tracking engine and forecasted heat movement from scheduling engines to predict the thermal loss during ladle transfer and predicts the correct lift temperature at ladle furnace. This results in better superheat compliance at the caster, eliminating caster slowdowns, hence increasing productivity.

Steelmakers can expect ABB Ability™ Smart Melt Shop to help increase superheat compliance to enable 4-5 percent higher casting speeds to improve productivity and reduce arcing by 5 degrees Celsius per heat in ladle furnaces for increased energy and cost efficiency.

ABB Ability™ Smart Melt Shop has already been installed by JSW Steel Ltd, India’s leading steel company, where it has been integrated into a wider expansion at Dolvi Works plant in Maharashtra state. It is expected to increase the company’s EBITDA profit by around $2million per annum through 4 percent higher casting speeds, time savings of one working day per month and additional output equating to 24,000 tons a year.

“We’re proud to launch ABB Ability™ Smart Melt Shop – the first of its kind in the metals industry, enabling steelmakers to digitally connect all processes and moving equipment in the melt shop, achieving synchronized operations and removing bottlenecks in production capacity,” said Tarun Mathur, Global Product Manager, Metals Digital, ABB. “The digitalization of core processes will drive new levels of productivity, safety and sustainability outcomes for the metals sector.”

This application uses all standard communications protocols, employs ABB’s multi-layered defense-in-depth approach to cyber security and is compatible with both ABB and third-party systems.

@ABB @abb_automation @ABBmetals #PAuto #Digitisation

Metal surface inspection.

An informative guide for metals manufacturers looking to achieve both high quality and yield optimization is now available from Ametek Surface Vision.

The Metals Surface Inspection Guide is a ready reference for Surface Vision’s SmartView® surface inspection system, one of the most trusted and valued automatic surface inspection solutions in the world.

A proven partner for increasing efficiency and improving product quality in the metals industry for over three decades, SmartView continues to be a market leader in the highly precise real-time detection and classification of metal defects.

The new guide outlines the benefits of the system’s real-time video and modular design flexibility for steel, aluminum and alloy manufacturers looking to improve the quality of their production through the highly configurable inspection and reporting SmartView offers.

Highly customizable to individual customer process needs, SmartView’s reliable top and bottom real-time optical inspection provides surface quality visibility in even the most-demanding metal processing environments. Combining powerful software, line-scan camera technology, high intensity lighting, and supported by industry-leading application knowledge and engineering services, SmartView’s automatic detection, classification and visualization of metal defects make it effective in a wide range of metal process applications, including scalpers, hot mills, cold rolling mills, annealing lines, coating lines and slitters.

“No other solution offers the flexibility and ease-of-use that SmartView delivers, and our new guide makes that clear. Our approach is simple: to provide the latest and best inspection solution for each application, delivered with the highest consistency and without compromise” commented Jason Zyglis, Divisional Vice President of Project and Product Management, Ametek Surface Vision.

@surfacevision #PAuto

Wireless safety foot switches.

To avoid failures during routine work due to hot metal splashes that damage the power or signal cables, a wireless safety foot switch using Steute “sWave 2.4 GHZ-safe” technology has been chosen. It greatly increases reliability while being easy to install and flexible.

The foundry profits from a longer lifespan
of the foot switches because there are no
longer cables which can be damaged
by hot metal splashes.

Foot switches are standard control elements in many metalworking enterprises. Operators have both hands free to start or stop a machine or drive. Because foot switches can be placed anywhere on the floor, they also offer a high degree of ergonomic comfort.

Foot switch advantages
It is precisely these advantages which a light metal foundry in Switzerland is currently exploiting. It manufactures high-quality cast aluminium parts, amongst other things for electrotechnology, railroad engineering and machine building. Machinery at the foundry includes tiltable gravity casting machines which were previously operated via cabled safety foot switches. These machines perform dangerous (tilting) movements during casting.

The search for an alternative
The switches repeatedly failed during routine work because hot metal splashes damaged the power or signal cables. In their search for an alternative, the technical management at the foundry came across a wireless safety foot switch which had just come onto the market and which communicated with the evaluating unit in the control cabinet via a safe wireless protocol.

New: wireless protocol for safety applications
This series of switchgear is the first to work with the safe wireless protocol “sWave® 2.4 GHz-safe” developed by steute. This wireless system uses the physical layer of standard IEEE 802.15.1. Due to a high level of reliability which is guaranteed, amongst other things, by the FHSS (“Frequency Hopping Spread Spectrum”) procedure on 79 channels and by the adaptive frequency hopping procedure, as well as to a very good coexistence with other wireless systems, it is especially suited to use in rough industrial environments. The transmitter/receiver system – as is to be expected from safety applications – is fundamentally designed as a two-channel system.

Several safe foot switches can work in parallel within one radio range. The power supply is battery-based, creating the conditions necessary for a highly accessible bidirectional radio connection. The system, consisting of the wireless foot switch and the receiver unit, is EC type examination tested and in Performance Level (PL) d according to ISO EN 13849-1, as well as Safety Integrated Level (SIL) 2 according to IEC 62061.

“Misappropriation” for new technology
The wireless safety foot switches were originally developed for special operations, such as the “setting mode” or “process monitoring mode”. Here the machines can still be operated in compliance with the standards, with opened guard doors and reduced speed, as long as the user actuates the pedal and keeps it depressed in the middle position.

A test at the foundry quickly showed, however, that the safety foot switch could just as effectively be used in this application. By doing away with the cable connection, the lifespan of the foot switch in this environment increases significantly. Ergonomic comfort is also improved because there is no cable to get in the way.

All steute foot switches are renowned for their ergonomic design. They are also extremely stable once positioned, which for this type of switch is an important criterion for ergonomic and intuitive operation. The metal housing can withstand a high degree of mechanical wear and tear and, like the high-quality switching inserts, makes for a long lifespan, even in rough ambient conditions – in foundries and elsewhere.