Implementation of a Real-time Model-based Spray-cooling Control System for Steel Continuous Casting

Bryan Petrus, Kai Zheng, Xiaoxu Zhou, Brian G. Thomas, Joseph Bentsman, Ron O. Malley

Research output: Chapter in Book/Report/Conference proceedingChapter


In continuous casting of steel, maintaining the shell surface temperature profile under transient conditions is important to minimize surface cracks. For this purpose a spray-cooling control system, CONONLINE, has been implemented on a commercial caster. The system includes a software sensor of shell surface temperature, control algorithm, and a monitor allowing operator input and displaying the predicted shell surface temperature profiles and other important operating data. Simulation results demonstrate that the new control system achieves better temperature control performance than conventional systems during a change in casting speed. Plant trials have shown that the performance can be improved by modifying the classical anti-windup method, and modifying the control algorithm during unusual casting conditions.

Original languageEnglish (US)
Title of host publicationSensors, Sampling, and Simulation for Process Control
PublisherJohn Wiley & Sons, Ltd.
Number of pages8
ISBN (Print)9781118036181
StatePublished - Apr 19 2011


  • Heat transfer
  • Proportional-integral control
  • Real-time simulation
  • Secondary cooling
  • Solidification model
  • Thin slabs

ASJC Scopus subject areas

  • General Materials Science


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