Advanced Tools and Techniques for steel casting
SUNSHINE explores innovative tools and methodologies designed to enhance the steel casting process. Our project focuses on improving the quality and efficiency of steel production through advanced modeling, sensor systems, and data analytics.
Modeling Tools
1. CFD-Based Digital Twin: Developed in the RFCS project RealTimeCastSupport, this tool computes the turbulent flow field through the SEN and within the Cu-mould. It predicts solidified steel shell thickness and local heat transfer, aiming to avoid defects caused by asymmetric flow conditions.
2. IDS and Tempsimu:
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IDS: A thermodynamic-kinetic-empirical software package simulating solidification and cooling-related microstructural phenomena. It helps in understanding phase transformations and their impact on steel quality.
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Tempsimu: A heat transfer modeling software for continuous casting, calculating strand and mould temperatures, shell thickness, and total mould heat flux. It includes a thermomechanical module to assess bending and straightening strains.
Sensor Systems
1. Shape Measurement: Sidenor and Feralpi are implementing advanced shape measurement systems using optical cameras and laser scanners. These systems detect irregular shapes and provide real-time alerts to maintain optimal casting conditions.
2. Fiber Optical Temperature Sensors (FOTS): AGDH's continuous caster will be equipped with FOTS for high-resolution temperature monitoring. This system offers advantages like increased spatial resolution, no electromagnetic interference, and flexibility in measurement locations.
Data Analytics
1. IoT Platforms and Machine Learning Techniques: Using data from sensors and process control systems, we develop predictive models to anticipate defects and optimize casting parameters. Machine learning techniques like Autoencoder and reinforcement learning are employed for real-time data analysis.
2. Online Monitoring Systems: Our comprehensive monitoring system integrates sensor data and modeling results to provide real-time recommendations for casting parameter adjustments. This helps prevent defects and ensures high-quality steel production.
Innovative Solutions
Decision Support System: A robust decision support system will be implemented to provide guidelines and alerts for maintaining optimal casting conditions. This system will integrate feedback from rolling, reheating, and welding processes to ensure continuous improvement.