A transient simulation and dynamic spray cooling control model for continuous steel casting

Hardin, Richard A.; Li, Kai; Kapoor, A N; Beckermann, C.

doi:10.1007/s11663-003-0075-0

Cited by 122 publications

(84 citation statements)

References 10 publications

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“…[42] (a) (b) Fig. 8-Secondary cooling during continuous casting of steel: (a) typical arrangement of spray nozzles and support rolls [45] , (b) schematic of zones [25] , and (c) detail of water spray-cooling process [47] .…”

Section: A Mold (Or Primary) Coolingmentioning

confidence: 99%

“…For steel casting, banks of nozzles located between contact rolls beneath the mold spray water to cool the moving metal strand. Usually, the spray nozzles are arranged into banks or cooling zones, assigned to the top and bottom surfaces of particular strand segments, [45] as shown in Figure 8(a). The water is forced under high pressure as droplets that form a mist, which continuously impact upon the metal surface.…”

Section: B Water (Or Secondary) Coolingmentioning

confidence: 99%

“…Air-water mist cooling has helped to provide more uniform cooling in both casting and transverse directions, and hence avoids cracks by minimizing the localized temperature fluctuations caused by the undercooling and overcooling associated with water droplet spray jets. Furthermore, automatic control systems are available in the industry [45,88] to adjust the sprays according to changes in casting speed and thereby optimize secondary cooling conditions for transient conditions as well. These control systems make use of online computational models to ensure that each portion of the shell experiences the same cooling conditions.…”

Section: Optimization Of Water Coolingmentioning

confidence: 99%

“…Models such as CASIM, DYNCOOL, and DYSCOS have been adopted by the industry for online process control. [45] The University of Illinois at Urbana-Champaign (CON1D [25] /CON2D [95] ) and L'Ecole des Mines de Paris [96] have developed FE-based programs to study the fundamentals of the complex but industrially-relevant phenomena in the mold and spray-cooling regimes.…”

Section: Optimization Of Water Coolingmentioning

confidence: 99%

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The use of water cooling during the continuous casting of steel and aluminum alloys

Sengupta

Thomas

Wells

2005

Metall Mater Trans A

110

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In both continuous casting of steel slabs and direct chill (DC) casting of aluminum alloy ingots, water is used to cool the mold in the initial stages of solidification, and then below the mold, where it is in direct contact with the newly solidified surface of the metal. Water cooling affects the product quality by (1) controlling the heat removal rate that creates and cools the solid shell and (2) generating thermal stresses and strains inside the solidified metal. This work reviews the current stateof-the-art in water cooling for both processes, and draws insights by comparing and contrasting the different practices used in each process. The heat extraction coefficient during secondary cooling depends greatly on the surface temperature of the ingot, as represented by boiling water-cooling curves. Thus, the heat extraction rate varies dramatically with time, as the slab/ingot surface temperature changes. Sudden fluctuations in the temperature gradients within the solidifying metal cause thermal stresses, which often lead to cracks, especially near the solidification front, where even small tensile stresses can form hot tears. Hence, a tight control of spray cooling for steel, and practices such as CO 2 injection/pulse water cooling for aluminum, are now used to avoid sudden changes in the strand surface temperature. The goal in each process is to match the rate of heat removal at the surface with the internal supply of latent and sensible heat, in order to lower the metal surface temperature monotonically, until cooling is complete.

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Section: A Mold (Or Primary) Coolingmentioning

confidence: 99%

Section: B Water (Or Secondary) Coolingmentioning

confidence: 99%

Section: Optimization Of Water Coolingmentioning

confidence: 99%

Section: Optimization Of Water Coolingmentioning

confidence: 99%

See 2 more Smart Citations

The use of water cooling during the continuous casting of steel and aluminum alloys

Sengupta

Thomas

Wells

2005

Metall Mater Trans A

110

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“…Further problems arise in modeling heat transfer boundary conditions in the secondary cooling zones. Hardin at al [4] have calculated the heat transfer coefficient (HTC) from the equation developed by Nozaki at al [5]. This equation defines HTC as a power function of the water flux for spray cooling under film boiling regime only.…”

Section: Introductionmentioning

confidence: 99%

Analysis of the Slab Temperature, Thermal Stresses and Fractures Computed with the Implementation of Local and Average Boundary Conditions in the Secondary Cooling Zones

Hadała

Malinowski

Telejko

2016

Archives of Metallurgy and Materials

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The numerical simulations of the temperature fields have been accomplished for slab casting made of a low carbon steel. The casting process of slab of 1500 mm in width and 225 mm in height has been modeled. Two types of boundary condition models of heat transfer have been employed in numerical simulations. The heat transfer coefficient in the first boundary condition model was calculated from the formula which takes into account the slab surface temperature and water flow rate in each secondary cooling zone. The second boundary condition model defines the heat transfer coefficient around each water spray nozzle. The temperature fields resulting from the average in zones water flow rate and from the nozzles arrangement have been compared. The thermal stresses and deformations resulted from such temperature field have given higher values of fracture criterion at slab corners.

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

Petrus

Zheng

Zhou

et al. 2011

Sensors, Sampling, and Simulation for Process Control

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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.

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A transient simulation and dynamic spray cooling control model for continuous steel casting

Cited by 122 publications

References 10 publications

The use of water cooling during the continuous casting of steel and aluminum alloys

The use of water cooling during the continuous casting of steel and aluminum alloys

Analysis of the Slab Temperature, Thermal Stresses and Fractures Computed with the Implementation of Local and Average Boundary Conditions in the Secondary Cooling Zones

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

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