A Transient Simulation and Dynamic Spray Cooling ControlModel for Continuous Steel Casting

IN order to remain competitive in the worldwide market for continuously cast steel, steel producers are finding it increasingly important to implement process control improvements. Through superior production process monitoring and control, producers are improving steel quality and are meeting customers’ requirements for steel size, grade, quantity, and properties at the lowest cost. Computer models used for real-time/online prediction and control of continuous steel casters are fundamental tools in this effort. Accurate online prediction and control allows for flexibility in caster operation. It gives operators the capability to vary casting speeds while keeping process parameters such as slab surface temperatures and solidification end point within desired ranges. Such control capability results in more uniform cast material throughout an entire casting sequence. Leaving aside the benefits of online/real-time control models, offline transient modeling gives insight into the time-varying behavior of process variables and parameters, and a more thorough understanding of the casting process. The simplest method of caster spray cooling control is to deliver a prescribed amount of water flow that is proportional to the casting speed. Different proportions of flow to casting speed are delivered to the casting machine’s spray cooling water flow loops. These flow loops supply water to banks of spray nozzles that are arranged into spray cooling zones. Usually, these zones are assigned to a machine segment, or combination of segments, and are often divided A Transient Simulation and Dynamic Spray Cooling Control Model for Continuous Steel Casting