A transient simulation and dynamic spray cooling control model for continuous steel casting |
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Authors: | Richard A Hardin Kai Liu Christoph Beckermann Atul Kapoor |
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Affiliation: | (1) the Department of Mechanical and Industrial Engineering, The University of Iowa, 52242-1527 Iowa City, IA;(2) Present address: IPSCO Saskatchewan Inc., S4P 3C7 Regina, SK, Canada;(3) Cap Gemini Ernst and Young Canada Inc., M5K 1J5 Toronto, ON, Canada |
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Abstract: | A two-dimensional heat-transfer model for transient simulation and control of a continuous steel slab caster is presented.
Slab temperature and solidification are computed by the model as a function of time-varying casting speed, secondary spray
cooling water flow rates and temperature, slab thickness, steel chemistry, and pouring and ambient temperatures. Typically,
the solidification path, temperature-solid fraction relationship, is prescribed. However, if these data are not available,
a microsegregation solidification model that approximates the effects of steel chemistry and cooling rate is incorporated
in the caster model. Measured slab surface temperatures recorded from an operating caster are compared with predictions from
the transient model. These demonstrate that the model typically can predict the temperature response at the slab surface within
30 °C. Results of several simulations are given to demonstrate the effects of changing casting conditions on the slab thermal
profile, end of liquid pool, and solidification end point. A control methodology and algorithm suitable for online control
of a continuous casting machine is described, and the ability to control the surface temperature profile by dynamically adjusting
secondary spray cooling flow rates is demonstrated by simulation. Results from a preliminary version of the model that is
capable of running in real time are presented and are compared with the slower, but more realistic, version of the model. |
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