Real-time, model-based spray-cooling control system for steel continuous casting

Bryan Petrus; Kai Zheng; X. Zhou; Brian G. Thomas; Joseph Bentsman

doi:10.1007/s11663-010-9452-7

Real-time, model-based spray-cooling control system for steel continuous casting

Bryan Petrus, Kai Zheng, X. Zhou, Brian G. Thomas, Joseph Bentsman

Research output: Contribution to journal › Article › peer-review

Abstract

This article presents a new system to control secondary cooling water sprays in continuous casting of thin steel slabs (CONONLINE). It uses real-time numerical simulation of heat transfer and solidification within the strand as a software sensor in place of unreliable temperature measurements. The one-dimensional finite-difference model, CON1D, is adapted to create the real-time predictor of the slab temperature and solidification state. During operation, the model is updated with data collected by the caster automation systems. A decentralized controller configuration based on a bank of proportional-integral controllers with antiwindup is developed to maintain the shell surface-temperature profile at a desired set point. A new method of set-point generation is proposed to account for measured mold heat flux variations. A user-friendly monitor visualizes the results and accepts set-point changes from the caster operator. Example simulations demonstrate how a significantly better shell surface-temperature control is achieved.

Original language	English (US)
Pages (from-to)	87-103
Number of pages	17
Journal	Metallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science
Volume	42
Issue number	1
DOIs	https://doi.org/10.1007/s11663-010-9452-7
State	Published - Feb 2011

ASJC Scopus subject areas

Condensed Matter Physics
Mechanics of Materials
Metals and Alloys
Materials Chemistry

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10.1007/s11663-010-9452-7

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title = "Real-time, model-based spray-cooling control system for steel continuous casting",

abstract = "This article presents a new system to control secondary cooling water sprays in continuous casting of thin steel slabs (CONONLINE). It uses real-time numerical simulation of heat transfer and solidification within the strand as a software sensor in place of unreliable temperature measurements. The one-dimensional finite-difference model, CON1D, is adapted to create the real-time predictor of the slab temperature and solidification state. During operation, the model is updated with data collected by the caster automation systems. A decentralized controller configuration based on a bank of proportional-integral controllers with antiwindup is developed to maintain the shell surface-temperature profile at a desired set point. A new method of set-point generation is proposed to account for measured mold heat flux variations. A user-friendly monitor visualizes the results and accepts set-point changes from the caster operator. Example simulations demonstrate how a significantly better shell surface-temperature control is achieved.",

author = "Bryan Petrus and Kai Zheng and X. Zhou and Thomas, {Brian G.} and Joseph Bentsman",

note = "Ron O{\textquoteright}Malley, Matthew Smith, Terri Morris, and Kris Sledge from Nucor Decatur are gratefully acknowledged for their unwavering support and help with this work. The TCP/IP programs in CONON-LINE were written by Rob Oldroyd from DBR Systems on behalf of Nucor Decatur. We are grateful for work on CON1D calibration for the Nucor Decatur steel mill by Sami Vahpalahti and Huan Li from the University of Illinois. We are also very grateful for their work on CONONLINE. This work is supported by the National Science Foundation under Grants DMI 05-00453 and CMMI-0900138 as well as the Continuous Casting Consortium at UIUC.",

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N1 - Ron O’Malley, Matthew Smith, Terri Morris, and Kris Sledge from Nucor Decatur are gratefully acknowledged for their unwavering support and help with this work. The TCP/IP programs in CONON-LINE were written by Rob Oldroyd from DBR Systems on behalf of Nucor Decatur. We are grateful for work on CON1D calibration for the Nucor Decatur steel mill by Sami Vahpalahti and Huan Li from the University of Illinois. We are also very grateful for their work on CONONLINE. This work is supported by the National Science Foundation under Grants DMI 05-00453 and CMMI-0900138 as well as the Continuous Casting Consortium at UIUC.

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N2 - This article presents a new system to control secondary cooling water sprays in continuous casting of thin steel slabs (CONONLINE). It uses real-time numerical simulation of heat transfer and solidification within the strand as a software sensor in place of unreliable temperature measurements. The one-dimensional finite-difference model, CON1D, is adapted to create the real-time predictor of the slab temperature and solidification state. During operation, the model is updated with data collected by the caster automation systems. A decentralized controller configuration based on a bank of proportional-integral controllers with antiwindup is developed to maintain the shell surface-temperature profile at a desired set point. A new method of set-point generation is proposed to account for measured mold heat flux variations. A user-friendly monitor visualizes the results and accepts set-point changes from the caster operator. Example simulations demonstrate how a significantly better shell surface-temperature control is achieved.

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Real-time, model-based spray-cooling control system for steel continuous casting

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