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 journalArticlepeer-review


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 languageEnglish (US)
Pages (from-to)87-103
Number of pages17
JournalMetallurgical and Materials Transactions B: Process Metallurgy and Materials Processing Science
Issue number1
StatePublished - Feb 2011

ASJC Scopus subject areas

  • Condensed Matter Physics
  • Mechanics of Materials
  • Metals and Alloys
  • Materials Chemistry


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