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The LD (Linz Donawitz) steelmaking process is the most used in the steel industry due to its high-volume capacity and low cost per ton of steel produced. However, the basic oxygen steelmaking process in LD converters is subjected to potential steel charge overflows, often called ‘slopping’. Besides yield losses, slopping events can damage the environment and expose employees to danger. More than ever, steelmaking plants need to avoid this type of event to keep producing as environmental impacts are no more tolerable by society. Steelmaking plants already use different methods to monitor and detect slopping events, but they are often limited and unreliable. Therefore, this paper proposes a multi-sensor data fusion process to generate a reliable slopping index to warn operators of potential slopping events and detect the triggered ones. The work is based on sound and image data (67 heats with 27 slopping events) collected on previous trials at a 350-ton LD converter. The Kalman filter was applied as a data fusion agent of two indexes, one resulted from computer vision analysis of the LD converter mouth (image data), the other resulted from digital signal analysis of sound captured on the converter’s hood (sound data). Fuzzy sets were applied for adaptative tuning of the Kalman filter to improve the data fusion process. Besides the increase of alarm accuracy and heat classification, the data fusion index worked better on different scenarios and produced a more reliable indicator for a slopping prevention system.

Slopping index for LD converters based on sound and image data fusion by fuzzy Kalman filter