Real-Time, Model-Based Spray-Cooling Control System for Steel Continuous Casting

• DOI: 10.1007/s11663-010-9452-7
• Publication Date: 2010-12-06T16:30:13Z
• Authors: Bryan Petrus; Kai Zheng; X. Zhou; Brian G. Thomas; Joseph Bentsman
• Keywords: Caster; Slab

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.