Mathematical and Fuzzy Model for Slag Thickness Control Automation in Gas-Stirred Ladle

The control of slag formation in steelmaking processes is crucial for ensuring the quality of the final product. This study presents a comprehensive approach to minimizing slag-free areas (“eyes”) in the slag layer of an argon-stirred steel melt in a ladle equipped with tuyeres. A combination of mathematical modeling, specifically the Navier-Stokes equations, and a full factorial experiment design is employed to predict the size of slag “eyes” and understand their dependency on key process parameters such as ladle size, tuyeres count, slag layer thickness and gas flow rate. The obtained predictions are utilized to develop fuzzy rules for a fuzzy control system, with parameters including gas flow rate, slag layer thickness, ladle size, and tuyeres count as inputs. The fuzzy control system demonstrated optimization capabilities, dynamically adjusting gas flow rates to minimize slag-free areas. The system’s adaptability to variations in ladle conditions contributes to robust and efficient steelmaking operations.