Design and implementation of an automated secondary cooling system for the continuous casting of billets

Chaudhuri, Subhasis; Singh, Rajeev Kumar; Patwari, Kuntal; Majumdar, Susanta; Ray, Asim K.; Singh, Arun K.; Neogi, Nirbhar

doi:10.1016/j.isatra.2009.09.005

Cited by 43 publications

(25 citation statements)

References 13 publications

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“…where T sur f is the surface temperature of billet, T W is the temperature of cooling water, and h is the integrative heat transfer coefficient, which can be calculated using the following equations: Foot-roller zone [28]: …”

Section: Moving Wallmentioning

confidence: 99%

Three-Dimensional Numerical Modeling of Macrosegregation in Continuously Cast Billets

Dong

Zhang

Yin

et al. 2017

Metals

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Macrosegregation, serving as a major defect in billets, can severely degrade material homogeneity. Better understanding of the physical characteristics of macrosegregation through numerical simulation could significantly contribute to the segregation control. The main purpose of this study was to predict macrosegregation in continuously cast billets with a newly developed three-dimensional macrosegregation model. The fluid flow, solidification, and solute transport in the entire billet region were solved and analyzed. Flow patterns, revealing a typical melt recirculation at the upper region of mold and thermosolutal convection at the secondary cooling zone, significantly affect the solidification and solute distribution. The solute redistribution occurring with thermosolutal convection at the solidification front contributes significantly to continued macrosegregation as solidification proceeds. The results of this study show that the equilibrium partition coefficient is mostly responsible for the magnitude of macrosegregation, while comparison between solute P and S indicated that diffusion coefficients also have some amount of influence. Typical macrosegregation patterns containing a positively segregated peak at the centerline and negatively segregated minima at either side were obtained via the proposed three-dimensional macrosegregation model, which validated by the measured surface temperatures and segregation degree.

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Section: Moving Wallmentioning

confidence: 99%

Three-Dimensional Numerical Modeling of Macrosegregation in Continuously Cast Billets

Dong

Zhang

Yin

et al. 2017

Metals

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“…The main technological parameter-necessary to compute the heat transfer coefficient-is the cooling intensity, most often given in dm 3 ·min −1 , which divided by the area of an individual spray zone allows the water flux density to be computed for the selected casting speed. In the literature [1,2,7,11,[39][40][41][42][43], we can find many models, which allow the heat transfer coefficient to be computed in a selected spray zone as a function of the solidifying strand surface temperature. One needs to emphasise that for the primary and secondary cooling zones there is no single universal heat transfer model, which would allow the correct value of heat transfer coefficient to be computed.…”

Section: Number Of the Htcmentioning

confidence: 99%

Control and Design of the Steel Continuous Casting Process Based on Advanced Numerical Models

Miłkowska-Piszczek

Falkus

2018

Metals

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The process of continuous casting of steel is a complex technological task, including issues related to heat transfer, the steel solidification process, liquid metal flow and phase transitions in the solid state. This involves considerable difficulty in creating the optimal process control system, which would include the influence of all the physico‐chemical phenomena which may occur. In parallel, there is an intensive development of new mathematical models and an increase in computer performance, therefore complex numerical simulations requiring substantial computing time can be conducted. This paper presents a review of currently applied numerical methods allowing the phenomena accompanying the process of continuous casting of steel to be accurately represented. Special attention was paid to the selection of appropriate methods to solve the technological problem selected. The possibilities of applying selected numerical models were analysed in order to modify and improve the existing process or to design a new one linked to the implementation of new steel grades in the current production. The description of the method of defining the boundary conditions, initial conditions and material parameters as vital components ensuring that numerical calculations based upon them in the finite element method, which is that most frequently applied, are correct is an important element of the paper. The possibility of reliably defining the values of boundary parameters on the basis of information on the intensity of cooling in individual zones of the continuous casting machine was analysed.

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“…In the calculation before calibration, the parameters are derived from literatures. 16,18) The parameters are not reliable when transfer them from one caster to another, for the spray conditions are quite different, so calibration is a must before online application. The casting steel grade is 65# and the casting speed is 1.75 m/min.…”

Section: Model Calibrationmentioning

confidence: 99%

Real-time Heat Transfer Model Based on Variable Non-uniform Grid for Dynamic Control of Continuous Casting Billets

Yang

Xie

et al. 2014

ISIJ Int.

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A real-time heat transfer model has been developed for dynamic control of continuous casting billets. In order to fulfill the real-time requirements for efficiency and accuracy, finite volume method (FVM) and alternating direction implicit algorithm (ADI) have been selected as the efficient numerical solution algorithm. And most important of all, variable non-uniform grid and variable time step have been adopted in the algorithm, accelerating the calculation of heat transfer model by 20-40 times. Further, the algorithm's discretization parameters including the grid, time step and slice distance have been optimized by error control (< 3°C), improving the relative calculation time to 0.57. The real-time model has been calibrated by surface temperature measurements using a thermal infrared imager, and its online performance has been tested, within ±13°C of the measurements. After the calibration, the model has been applied to the dynamic control of secondary cooling and the dynamic control of the electric current of final electromagnetic stirring (FEMS), providing the surface temperatures and mushy zone radius at the installation position of FEMS. The latter has been validated by shell-thickness measurements using nail-shooting (relative error< 2.3%). The model-based dynamic control systems controlled the surface temperatures and the flow in mushy zone precisely with changing casting conditions, and have improved the billet quality obviously and reduced the fractures of rolling line during wire-drawing to 1/6 times per month in average from 2-3 times before.

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Design and implementation of an automated secondary cooling system for the continuous casting of billets

Cited by 43 publications

References 13 publications

Three-Dimensional Numerical Modeling of Macrosegregation in Continuously Cast Billets

Three-Dimensional Numerical Modeling of Macrosegregation in Continuously Cast Billets

Control and Design of the Steel Continuous Casting Process Based on Advanced Numerical Models

Real-time Heat Transfer Model Based on Variable Non-uniform Grid for Dynamic Control of Continuous Casting Billets

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