Metallurgy & Steel Industry Solutions

From blast furnace to rolling mill — every fluid measured

Steel plants run some of the most demanding fluid systems in heavy industry: high-temperature cooling circuits, dirty process gases, abrasive slurries, high-pressure hydraulics, and steam. Each requires a different measurement approach. This page maps the right instrument to each application.

Discuss Your Application

Production Areas We Cover

Where Flow Measurement Matters in Metallurgy & Steel

From ironmaking, steelmaking, casting, and rolling to non-ferrous smelting, refining, utilities, and wastewater treatment, metallurgical plants depend on accurate flow measurement across water, gas, steam, slurry, acid, and chemical service. We'll help you to match the right Flow measurement solutions for the real operating conditions behind each application.

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Blast Furnace & BOF / EAF Steelmaking

Furnace cooling circuits, oxygen lance metering, process gas (BF gas, COG, converter gas), ladle metallurgy, and mold /secondary cooling in continuous casting.

Furnace cooling

BF / COG gas

Caster cooling

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Hot & Cold Rolling / Surface Treatment

Descaling water (high pressure), roll and laminar cooling, hydraulic systems, and pickling and rinse circuits in cold rolling and strip finishing lines.

Descaling water

Roll cooling

Pickling acid

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Copper, Zinc & Lead Smelting / Refining

Smelter cooling water, electrolytic refining electrolyte circuits (copper sulfate, zinc sulfate), leach acid supply, electrowinning, and solvent extraction circuits.

Electrolyte circuits

Leach acid

Smelter cooling

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Aluminum Smelting & Refining

Caustic liquor (NaOH) in the Bayer digestion and precipitation process, electrolytic cell cooling, and compressed air and utility gas distribution in potrooms.

Caustic (NaOH)

Cell cooling

Bayer process

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Hydrometallurgy & Water Treatment

Leach slurry and tailings circuits, acid mine drainage, process effluent treatment, plant water distribution, and recirculating cooling water systems across all metals operations.

Leach slurry

Tailings

Effluent treatment

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Steam, Gas & Compressed Air

Steam supply to reheating furnaces and power generation, industrial gas distribution (O₂, N₂, Ar), compressed air for instrumentation and process, and natural gas to fired furnaces.

Process steam

Fuel gas

Compressed air

Fluid Measurement Coverage Map

Where Measurement Occurs Across the Mineral Processing Circuit

rom ore feed through to tailings disposal and effluent management — this map shows which fluid streams require measurement at each stage and which meter families apply.

Stage 01

Comminution & Grinding

Ore slurry feed

Grinding water

Mill discharge

Slurry EM (ore pulp)

Integrated EM (water)

Stage 02

Flotation & Classification

Flotation feed/froth

Cell air injection

Reagent dosing

Slurry EM (concentrate)

Thermal Mass (air)

Threaded EM (reagents)

Stage 03

Leaching & Hydromet

Sulfuric acid / cyanide

PLS / barren solution

SX-EW raffinate

EM PTFE/Hastelloy (acid)

Coriolis (specialty)

Stage 04

Thickening & Dewatering

Thickener underflow

Flocculant dosing

Overflow return

Slurry EM (underflow)

Coriolis (flocculant)

Integrated EM (overflow)

Stage 05

Tailings & Effluent

Tailings paste / slurry

AMD treatment

Discharge & drainage

Slurry EM (tailings)

EM PTFE (AMD)

Open Channel (drain)

Electromagnetic (Slurry & Integrated) Flowmeter

Thermal Mass & Vortex Flowmeter

Coriolis Mass Flowmeter

Open Channel / Ultrasonic Flowmeter

Insertion & Battery-Powered EM Flowmeter

Media diversity is the defining challenge

Cooling water, acid, slurry, steam, and gas require fundamentally different measurement principles. A selection error means a meter that either cannot measure the fluid at all, or fails within months.

Key Selection Challenges

Key Selection Challenges in Metallurgical Flow Measurement

Flow measurement in metallurgy is defined less by one industry label and more by the operating conditions behind each service. Large water circuits, dirty gases, abrasive slurries, corrosive chemicals, high temperatures, hazardous areas, and limited shutdown windows all influence which meter technology is practical and reliable.

Water circuits dominate by volume — and they require zero pressure drop

Furnace cooling, mold cooling, descaling, and laminar cooling circuits are the highest-volume measurement application in any steel or smelting facility. These circuits cannot tolerate obstruction-induced pressure loss — it reduces cooling effectiveness. Electromagnetic flowmeters with full-bore zero-obstruction tubes are the standard choice. For large-bore headers where shutdown is not possible, insertion EM meters install via hot-tap without interrupting flow.

Specification note: lining material must be matched to medium — rubber or polyurethane for abrasive scale-bearing water, PTFE/PFA for chemically aggressive circuits.

Acid, caustic, and electrolyte circuits require corrosion-resistant electrode and lining selection

Non-ferrous metallurgy — copper/zinc electrolytic refining, copper leaching, aluminum Bayer process, steel pickling — all involve measuring corrosive aqueous media. These are all conductive and therefore measurable by electromagnetic meters. What changes is the electrode and lining material: PTFE or PFA lining for acids, Hastelloy C or Tantalum electrodes for hydrochloric or sulfuric acid service, 316L for mild alkali. Specifying the wrong electrode corrodes through within weeks.

Specification note: always state the acid type, concentration, and temperature when ordering — electrode and lining selection depends on all three.

Process gases in steel are dirty, wet, and often pulsating — most meters cannot tolerate them

Blast furnace gas carries dust, moisture, and tar vapor. Converter gas fluctuates violently during blowing. These conditions eliminate turbine meters (fouling), standard vortex meters (minimum velocity limitations), and most DP meters with conventional impulse lines (plugging). After a gas cleaning plant, gas turbine meters serve fiscal metering of clean by-product gas well. For pre-cleaning or difficult service, V-Cone DP is typically shortlisted alongside proper gas sampling and conditioning design.

Specification note: BF/COG gas metering is not a "one meter solves it" situation — gas cleanliness and conditioning requirements must be established before instrument selection.

Slurry and abrasive wastewater erode standard meter linings rapidly

Mill scale slurry, ore leach pulp, and tailings pipelines carry hard angular particles that rapidly erode PTFE and standard elastomer linings. Polyurethane lining — with hardness rated for continuous abrasive service — is the correct choice for high-abrasion slurry. Natural rubber serves moderate-abrasion duty. Specifying PTFE on a mill scale slurry line typically results in lining perforation within months, requiring complete meter replacement.

Specification note: match lining to particle hardness and concentration; polyurethane for hard abrasives, rubber for soft/moderate duty.

Flammable process gas environments require verified explosion-proof group classification

BF gas, coke oven gas, and converter gas contain carbon monoxide and hydrogen at concentrations that classify measurement zones as Zone 1. Group IIB certification covers most hydrocarbon gases, but hydrogen-rich environments (which include parts of COG service) require Group IIC. This is not a general "ATEX compliant" question — the gas group must be confirmed against the actual gas composition and zone classification before specifying any instrument in a by-product gas environment.

Specification note: confirm gas group (IIB or IIC) from the hazardous area classification document for the specific installation point — not from a generic zone designation.

Find Your Application

Select your fluid type — find the right meter

Each tab covers a major fluid category in steel plant operations. Select the one that matches your measurement requirement and work through the specific scenarios.

01 - Furnace & smelter cooling

High-volume cooling water for furnace bodies and smelter cooling circuits

Blast furnace stave cooling, BOF/EAF cooling panels, and smelter furnace jackets all require continuous high-flow cooling water monitoring where any restriction on flow is a safety risk. Full-bore EM meters impose zero pressure drop. For large headers where shutdown is not possible, insertion EM meters install through a hot-tap fitting without interrupting flow.

Best fit: Main cooling headers DN100–DN600. Zero pressure drop is a hard requirement. Insertion option for large-bore no-shutdown installations.

Zero pressure drop

No shutdown

IP67 / IP68

DN100–DN3000

Integrated Magnetic Flowmeter Insertion Magnetic Flowmeter

02 - Mold & secondary cooling

Continuous caster mold cooling and secondary spray zone circuits

Each mold cooling circuit in a continuous caster requires individual flow monitoring — a deviation from setpoint is a potential breakout signal. Secondary cooling zones meter water per strand segment to control surface temperature along the target cooling curve. These are smaller-bore, accuracy-sensitive circuits in high-vibration environments.

Best fit: Individual mold circuits DN15–DN80; secondary spray zone headers DN25–DN150. Individual alarm output per circuit.

Per-circuit monitoring

Low-flow alarm

High vibration rated

Integrated Magnetic Flowmeter

03 - Descaling & laminar cooling

High-pressure descaling water and run-out table laminar cooling

Hot rolling descaling uses water at 15–25 MPa to remove mill scale before rolling. Laminar cooling meters water volume per unit strip length to control final coil microstructure. Both are high-pressure conductive water service. HBYB EM meters are pressure-rated to 42 MPa — a pressure range where most industrial EM meters are not rated.

Best fit: Descaling headers DN50–DN200 at up to 25 MPa. Confirm pressure rating against your actual operating and test pressure before specifying.

Up to 42 MPa rated

High-pressure water

Flow per strip length

Integrated Magnetic Flowmeter

01 - Blast furnace gas

BF gas metering — before and after the gas cleaning plant

Blast furnace gas is dirty, wet, and dust-laden before cleaning. Most meter technologies are not viable in this service without careful gas conditioning. After the gas cleaning plant, gas turbine meters serve fiscal allocation well on clean, dry gas. For pre-cleaning or difficult service, DP-type primary elements (including V-Cone) are typically shortlisted alongside a full gas conditioning and sampling system design.

Typically shortlisted: Gas Turbine (clean gas, post-cleaning, fiscal duty). V-Cone DP (dirty/wet gas, pre-cleaning, with appropriate conditioning). Gas cleaning and pretreatment requirements must be defined before meter selection.

Gas cleanliness first

ExdIIC certified

Pretreatment design required

Gas Turbine Flowmeter

V-Cone Flowmeter —for dirty gas with pulsating flow or challenging installation geometry

02 - COG & converter gas

Coke oven gas and converter gas — distribution and internal energy billing

After cleaning, COG and converter gas are high-calorific fuels distributed throughout the plant as internal energy. Metering their distribution requires custody-level accuracy and direct standard volume (Nm³/h) output that accounts for temperature and pressure. Gas turbine meters with integrated T/P compensation are typically used for clean by-product gas fiscal metering once sufficient gas conditioning is confirmed.

Best fit: Clean, dry COG and converter gas after cleaning plant, DN50–DN300. Requires pre-meter filtration and moisture removal — confirm gas cleanliness specification before ordering.

Clean dry gas required

±0.5% Class 5

Integrated T/P comp.

ExdIIC option

Gas Turbine Flowmeter

03 - Natural gas supply

Natural gas to reheating furnaces, annealing lines, and process burners

Natural gas metering for energy billing and combustion control on furnace supply lines. Clean, dry natural gas at modest operating pressures is a straightforward gas turbine application. Gas turbine meters with integrated T/P compensation output Nm³/h directly for billing and combustion control without a separate flow computer. ATEX certification required for classified zones.

Typically shortlisted: Gas Turbine with T/P compensation, DN50–DN200. Gas must be clean and dry before the meter — install a filter/separator if moisture or condensate is possible.

Clean dry gas required

Integrated T/P comp.

Direct Nm³/h output

ATEX certified

Gas Turbine Flowmeter

03 - Combustion air metering

Combustion air supply to blast furnace stoves, reheating furnaces, and industrial burners

Combustion air metering in metallurgical applications covers a wide range of conditions — from ambient-temperature burner air on smaller furnaces to the high-temperature, high-volume hot blast circuits on blast furnace stoves. The correct technology depends heavily on operating temperature, pipe size, installation constraints, and whether mass flow or volumetric indication is needed. For ambient-temperature large-bore air mains, insertion thermal mass meters are typically shortlisted. For hot blast or high-temperature service, installation conditions and temperature profile must be confirmed before specifying any instrument.

Typically shortlisted: Insertion Thermal Mass (ambient-temperature combustion air, DN200+, hot-tap). Technology selection for hot blast or high-temperature air requires site-specific review — confirm operating temperature range and installation envelope before shortlisting.

Ambient air: thermal mass

High-temp service: site review

Confirm temperature first

Insertion Thermal Mass Flowmeter

— for high-temperature combustion air or hot blast service: contact us for site-specific shortlist

01 - Oxygen injection

Oxygen supply to BOF converters, ladle furnaces, and EAF injectors

BOF oxygen lances consume large oxygen volumes during the blowing period — mass flow rate controls the decarburization rate. EAF oxygen injectors use O₂ for post-combustion and foaming slag control. These are clean, pure O₂ lines where thermal mass meters calibrated for oxygen and assembled with oil-free, oxygen-compatible materials are typically used. Oxygen service is materials-sensitive — standard instruments are not suitable without specific material preparation.

Best fit: O₂ supply to converters and EAF injectors DN50–DN150. Requires O₂-compatible wetted materials and oil-free assembly — specify O₂ service explicitly when ordering.

O₂-compatible materials

Gas-specific calibration

Direct Nm³/h output

Inline Thermal Mass Flowmeter

02 - Nitrogen & argon

Nitrogen and argon for ladle stirring, heat treatment, and protective atmospheres

Ladle furnace argon stirring controls inclusion flotation and temperature homogenization in steelmaking. Heat treatment furnace protective atmospheres use nitrogen and nitrogen-hydrogen blends. Each gas requires its own calibration — N₂-calibrated meters will not accurately measure Ar or H₂ blends. Specify gas type, composition, and flow range when ordering.

Best fit: Ar ladle stirring lines DN15–DN50; N₂/N₂-H₂ atmosphere supply DN25–DN100. Gas-specific calibration mandatory — different gases require separate instruments.

N₂ or Ar calibration

Direct Nm³/h output

Integrated T/P compensation

Inline Thermal Mass Flowmeter

02 - Compressed air

Instrument air and process compressed air metering across the plant

Compressed air powers pneumatic valves, instrument systems, and process tools across metals facilities. Metering at the compressor outlet and at zone distribution feeds enables energy management and leak detection. Large-bore mains are served by insertion meters via hot-tap without shutdown. Small-bore instrument air supply to control system zones is served by inline meters.

Best fit: Compressed air mains DN80–DN600 (insertion, hot-tap). Zone branch feeds and instrument air DN15–DN100 (inline).

Air-calibrated

Hot-tap option available

200:1 turndown for leak detection

Insertion Thermal Mass Flowmeter

01 - Reheating furnace & process steam

Steam supply to reheating furnaces, annealing lines, and process consumers

Reheating furnaces, soaking pits, and annealing lines use steam for atmosphere control and process heating. Vortex meters with no moving parts in the flow path operate reliably at temperatures up to 350°C with no scheduled maintenance on the flow element — and are the most common shortlisted technology for industrial process steam in metallurgical plants. The multivariable vortex, with integrated T/P compensation, outputs mass steam flow without a separate flow computer.

Typically shortlisted: Vortex for process steam, saturated or superheated, DN25–DN300 at up to 350°C. Multivariable vortex where direct mass flow or energy output (GJ/h) is required.

Up to 350°C

No moving parts

Sat. & superheated steam

Multivariable Vortex Flowmeter

Flanged Vortex Flowmeter — where mass flow output is not required and a separate flow computer is acceptable

02 - Plant steam distribution & condensate

Steam header metering for energy allocation and condensate return monitoring

Integrated plants meter steam at each major consumer for energy cost allocation and steam balance calculation across production units. Condensate return lines are conductive hot water — electromagnetic flowmeters provide accurate measurement with no pressure drop, making them practical for confirming steam trap performance and heat exchanger efficiency. Condensate circuit EM meters are a simple, low-maintenance addition to the steam monitoring system.

Typically shortlisted: Vortex or Multivariable Vortex for steam headers. Electromagnetic for condensate return lines.

Steam energy allocation

Condensate: Magnetic flowmeter

Steam trap monitoring

Flanged Vortex Flowmeter

Integrated Magnetic Flowmeter — for condensate return lines specifically

01 - Mill scale slurry

Mill scale slurry return circuits from hot rolling descaling pits

Descaling water returns to the scale pit carrying hard, angular mill scale particles. This is one of the most abrasive services in a steel plant. PTFE lining perforates within months in this duty. The slurry-type EM meter with polyurethane lining is the correct selection — polyurethane is rated for continuous abrasive slurry service where standard linings fail.

Best fit: Mill scale slurry return DN50–DN300. Polyurethane lining required — do not specify PTFE lining for this service.

Polyurethane lining

Abrasive slurry rated

Full-bore design

Slurry-Type Magnetic Flowmeter

02 - Ore leach slurry & tailings

Ore pulp, leach slurry, and tailings pipelines in hydrometallurgy

Hydrometallurgical operations grind ore and leach it with acid — the resulting ore pulp and tailings slurry carry abrasive mineral particles in acidic media. This combination demands a meter that handles both abrasion and chemical attack: EM meters with rubber or polyurethane linings and corrosion-resistant electrodes (Hastelloy C or titanium) serve this service. Lining and electrode selection depends on particle hardness, acid concentration, and temperature.

Best fit: Ore pulp and tailings DN100–DN600. Specify lining and electrode material based on particle hardness, acid type, and concentration.

Rubber / polyurethane lining

Hastelloy C or Ti electrodes

Abrasion + acid combined

Slurry-Type Magnetic Flowmeter

02 - Process effluent & water treatment

Plant effluent discharge, recirculating water systems, and water treatment plant flows

Steel and metals plants discharge cooling tower blowdown, acid rinse water, and treated process effluent under environmental permit conditions that require metered flow records. Recirculating cooling water systems benefit from flow monitoring to identify heat exchanger fouling. For large-diameter gravity drainage channels with partially-filled flow, partially-filled magnetic flowmeters measure without requiring a full pipe condition.

Typically shortlisted: Integrated Magnetic flowmeter for pressurized effluent headers. Partially-Filled Magnetic flowmeter for open channels and gravity drain lines.

Environmental compliance

Partially-filled option

Chemical-resistant lining

Integrated Magnetic Flowmeter

Partially-Filled Magnetic Flowmeter— for open channels and gravity drainage where full pipe flow is not guaranteed

01 - Electrolytic refining circuits

Electrolyte flow in copper, zinc, and nickel electrolytic refining and electrowinning

Electrolytic refining (copper, zinc, nickel) and electrowinning (copper SX-EW) circulate acidic metal sulfate electrolyte — copper sulfate or zinc sulfate at concentrations of 100–200 g/L, typically in dilute sulfuric acid. These are conductive solutions measurable by EM meters with PTFE or PFA lining and 316L or Hastelloy electrodes, depending on acid concentration. Flow rate directly affects current density distribution and therefore metal deposit quality.

Best fit: Electrolyte circulation loops DN50–DN200. PTFE or PFA lining; electrode material confirmed against acid concentration and temperature.

PTFE / PFA lining

316L or Hastelloy electrode

Metal sulfate + dilute H₂SO₄

Integrated Magnetic Flowmeter

02 - Sulfuric acid & leach solutions

Sulfuric acid supply to heap leaching pads and acid leach circuits

Copper and zinc hydrometallurgy uses sulfuric acid (5–20% concentration) for heap leaching or tank leaching. Metering acid supply to leach pads controls acid consumption per unit of metal recovered. Dilute sulfuric acid is conductive and measurable by EM meters — the critical selection parameter is lining and electrode compatibility. PTFE or PFA lining combined with Hastelloy C electrodes is the established material combination for dilute H₂SO₄ service.

Best fit: H₂SO₄ supply to leach circuits DN25–DN200. Specify acid concentration and temperature — both affect electrode and lining selection.

PTFE / PFA lining required

Hastelloy C electrodes

Confirm concentration + temp

Integrated Magnetic Flowmeter

02 - Pickling & caustic circuits

Hydrochloric acid pickling, rinse water, and caustic circuits in steel cold rolling and aluminum refining

Steel cold rolling pickling lines use hydrochloric acid (HCl, 3–15%) to remove oxide scale before cold reduction. Aluminum Bayer refining uses concentrated caustic soda (NaOH, up to 200 g/L) in the digestion and precipitation stages. Both are conductive aqueous solutions measurable by EM meters — but with different electrode requirements: Hastelloy C or Tantalum for HCl; 316L or rubber for caustic. Specifying the wrong electrode material accelerates corrosion and requires premature meter replacement.

Best fit: HCl pickling lines: PFA lining + Hastelloy C or Tantalum electrodes. NaOH caustic: rubber lining + 316L electrodes. State the specific chemical before ordering.

HCl: PFA + Hastelloy C / Tantalum

NaOH: rubber + 316L

Specify chemical before ordering

Integrated Magnetic Flowmeter

Instrument Requirements for Metals Processing

What this industry actually demands from instrumentation

Not product features — the selection requirements that differ between a correct specification and one that fails in service.

Electrode & Lining Material Selection

For every conductive liquid application, lining and electrode material selection is as critical as the meter type. PTFE for mild chemicals; PFA for concentrated acids; polyurethane for abrasive slurry; Hastelloy C for HCl; Tantalum for strongest acids.

Abrasion Resistance

Mill scale slurry, ore pulp, and tailings require polyurethane or natural rubber lining — materials rated for continuous abrasion. PTFE will not survive. Specify lining by particle hardness and concentration, not by default.

Explosion-Proof Classification

BF gas and COG environments are Zone 1. Confirm the gas group (IIB or IIC) from the area classification document — not from a generic “flammable gas” assumption. The correct group must match the actual gas composition.

High-Pressure Rating

Descaling water service can reach 20–25 MPa. HBYB EM meters are rated to 42 MPa — confirm the actual rated pressure on the datasheet before specifying for high-pressure applications. Most industrial EM meters are not rated above PN40.

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