Simulation and Techno-Economic Performance of a Novel Charge Calculation and Melt Optimization Planning Model for Steel Making

Abstract

Process algorithm, numerical model and techno-economic assessment of charge calculation and furnace bath optimization for target alloy for induction furnace-based steelmaking is presented in this study. The developed algorithm combines the make-to-order (MTO) and charge optimization planning (COP) of the steel melting shop in the production of target steel composition. Using a system-level approach, the unit operations involved in the melting process were analyzed with the purpose of initial charge calculation, prevailing alloy charge prediction and optimizing the sequence of melt chemistry modification. The model performance was established using real-time production data from a cast iron-based foundry with a 1-and 2-ton induction furnace capacity and a medium carbon-based foundry with a 10-and 15-ton induction furnace capacity. A simulation engine (CastMELT) was developed in Java IDE with a MySQL database for continuous interaction with changing process parameters to run the model for validation. The comparison between the model prediction and production results was analyzed for charge prediction, melt modification and ferroalloy optimization and possible cost savings. The model performance for elemental charge prediction and calculation purpose with respect to the charge input (at overall scrap meltdown) gave R-squared, Standard Error, Pearson correlation and Significance value of (0.934, 0.06, 0.97, 0.0003) for Carbon prediction, (0.962, 0.06, 0.98, 0.00009) for Silicon prediction, (0.999, 0.048, 0.999, 9E−11) for Manganese Prediction, and (0.997, 0.076, 0.999, 6E−7) for Chromium prediction respectively. Correlation analysis for melt modification (after charging of ferroalloy) using the model for after-alloying spark analysis compared with the target chemistry is at 99.82%. The results validate the suitability of the developed model as a functional system of induction furnace melting for combined charge calcula-

Melting Time Prediction Model for Induction Furnace Melting Using Specific Thermal Consumption from Material Charge Approach

“…The implication of this relationship between melt composition (elemental and mass constituents) and melting time is that the more time spent in balancing the material composition of an existing charge to achieve target melt, the more energy is consumed in a real-time foundry operation. Having established this relationship from this study, foundry shops will be able to do more in reducing their melting time from material balancing and charge preparations which could be from virtual simulation engines such CastMELT [20] used in this study or others such as (NovaCast, OPTI Melt, Cloud Foundry, and MKW). These simulation programs are foundry melting support tool to assist foundry and production engineers to plan their melting campaign ahead for material charge and optimization.…”