The use of artificial intelligence technique for the optimisation of process parameters used in the continuous casting of steel

The productivity and quality of a continuous caster depend mainly on process parameters, i.e. casting speed, casting temperature, steel composition and cleanliness of the melt, water flow rates in the different cooling zones, etc. This work presents the development of an algorithm, which incorporates heuristic search techniques for direct application in metallurgical industries, particularly those using continuous casting process for the production of steel billets and slabs. This is done to determine the casting objectives of maximum casting rate as a function of casting constraints. These constraints are evaluated with the aid of a heat transfer and solidification model based on the finite difference technique, which has been developed and integrated with a genetic algorithm. The essential parts of continuous casting equipment, which must be subjected to monitoring, as well as a methodology of mathematical model and physical settlements in each cooling region, are presented. The efficiency of the intelligent system is assured by the optimisation of the continuous casting operation by maximum casting rate and defect-free products. This approach is applied to the real dimension of a steel continuous caster, in real conditions of operation, demonstrating that good results can be attained by using heuristic search, such as: smaller temperature gradients between sprays zones, reduction in water consumption and an increase in casting speed.     

连续铸钢保护渣热传递三维数值模拟

本文讨论了连续铸钢保护渣层热过程的物理 ,数学模型 ,采用三维有限元方法进行了数值计算 ,较成功地模拟了保护渣的热传递过程     

An analytical solution for the unidirectional solidification problem

The extraction of heat from a molten casting is resisted by an imperfect thermal contact at the mold-casting interface. The nature of the contact varies throughout the casting process and has the effect of increasing the thermal resistance at the interface. This can be modelled by incorporating a gaseous gap at the mold-casting interface that grows with increasing time.

This paper is concerned with an analytical solution of the unidirectional solidification problem, which incorporates movement of the casting at the interface. The derivation of the analytical solution requires the simultaneous solution of the transient heat equations, for the mold, gaseous gap, and solid and liquid parts of the melt. The analytical solution is extended so that contamination layers on the mold and casting can be incorporated as well as an initial gap. This is achieved by introducing virtual layers of mold, gas, and casting. Using the extended solution, the effects of interfacial resistance, air conductivity, and gap variation on solidification rates are examined.     

A study of the continuous casting mold using a pareto-converging genetic algorithm

The mold region of the continuous caster, the most widely used casting device used by the steel industry has been modeled through a combination of a steady-state heat transfer approach and a recently developed pareto-converging genetic algorithm (PCGA). Due to highly non-linear nature of the objective functions, as well as the constraints, locating the pareto-front was quite a challenging job in this case. Also, from a physical consideration, the pareto-front needed to be zoomed into the region of equality of two objective functions. PCGA could successfully locate the optima after an extensive search, and the predictions are well in accord with the data provided by a number of industrial casters.     

An approximation of the thermal field in a continuous casting process of a thin metal layer

We consider the problem of a phase change in a continuous casting process: molten bronze is poured on to a moving steel strip cooled from below, in order to solidify the bronze. An estimate of the width of the solidification zone, depending on the thickness of the strip and on the casting velocity, is obtained, neglecting conduction in the direction of the strip motion.     

Strand straightening in the continuous casting of steel

In the continuous casting of steel, a strand with a solidifiededge is produced by pouring molten steel through a water-cooledmould. The strand is curved below the mould to travel horizontallyby a series of roll pairs. In this paper, the forces actingon these rolls and the stress and strain/strain rates withinthe steel are predicted. The mathematical model considers rigid-plasticand elastoplastic behaviour. A numerical solution procedurebased on computational fluid dynamics has been adapted to solvethe equations governing the material deformation. Algorithmsfor determining the location of the strand free surface andthe contact or noncontact of rolls are described.     

Oscillation of Confined Jets in Continuous Casting Mold Flow

In continuous slab casting, the liquid steel is introduced into the mould via a submergered entry nozzle. This nozzle usually has two opposed orifices on its side walls, generating two diametrically opposed turbulent jets that are declined about 20° to the horizontal axis. These jets interact with the surrounding walls of the mould, which leads to an unstable flow situation and a self induced oscillation of the jets. Although both mould and nozzle geometry have two perpendicular symmetry planes, the oscillations are asymmetric. The fluid flow inside the mold is calculated with a 3D finite volume solver using turbulence models based on Reynolds-averaging. The massflow of the jets and the mould extensions are varied, and the numerical results are partially compared with PIV-measurements at a 1:1 scaled watermodel of the mould. (© 2006 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

An effective heuristic algorithm to minimise stack shuffles in selecting steel slabs from the slab yard for heating and rolling

Steel production is a multi-stage process. A slab yard serves as a buffer between the continuous casting stage and the steel rolling stage. Steel slabs are stored in stacks in the yard. Shuffling is needed when picking up a slab for heating and rolling, if it is not in the top position of a stack. This paper studies the problem of selecting appropriate slabs in the yard for a given rolling schedule so as to minimise the total shuffling cost. The study uses the hot strip rolling mill in Shanghai Baoshan Iron and Steel Complex as an application background. We propose a new heuristic algorithm to solve the problem. This is a two-phase algorithm that first generates an initial feasible solution and then improves it using local search. The new algorithm is compared with the algorithm in use on randomly generated test problems and on real data. Experimental results show that the proposed algorithm yields significant better solutions. The average improvement over the old algorithm is 15%.     

Mathematical and physical modeling of systems for metal delivery in the continuous casting of steel and DC casting of aluminum

In the continuous casting of steel, various nozzles have been used (e.g., bifurcated nozzles with ports inclined at various angles to the horizontal) to deliver metal from the tundish into the caster. An even greater variety of devices is used in the case of semi-continuous (direct chill (DC) or electromagnetic (EM)) casting of aluminum, for example, nozzles delivering metal into bags of various designs. The paper describes a physical (water) model whereby particle image velocimetry has been used to measure velocities. These measured velocities are compared to ones predicted using computational fluid dynamics. Conclusions are reached concerning the validity of the computations and recommendations made about improvement in casting operations by modification of melt flow.     

连续铸钢问题的有限元解法及参数优化

本文介绍连续铸钢二冷区钢坯温度分布的计算以及喷水量的优化，钢铁工艺对二冷区钢坯温度有一定要求，将其量化为求代价泛函最小问题，对状态方程用有限元模拟遗传算法求问题的最小解，确定最佳喷水方案。     

Application of a heuristic search technique for the improvement of spray zones cooling conditions in continuously cast steel billets

The process of casting occupies an important place in the metallurgical industry, and the entire world of the metal user. In the past, the ingot casting–rolling (slabbing, blooming, or billeting) process was commonly used. The continuous casting process has largely replaced this earlier method because of the inherent advantages of energy savings, enhanced productivity, higher yield and reduced costs. However, continuous casting process is not without of its problems. Considerable effort has been made by many researches to establish adequate design, operation and maintenance of continuous casting machine to ensure metallurgical quality of the final product. One of the most severe defects in continuous casting products is concerned with the cracks provoked by improper design of the spray cooling system. The aim of this work is to develop a two dimensional heat transfer model based on the finite difference method in order to calculate the strand temperatures and the solid shell profile along the machine. An Artificial Intelligence heuristic search procedure interacts with the numerical model to determine the improved cooling conditions for the sprays zones of a real continuous caster for the production of quality billets.     

Fulfilling orders for steel plates from existing inventory

This paper investigates the steel plate order fulfilment problem from existing inventory, which is a generalization of one-dimensional cutting and packing problems. Semi-processed inventory of steel slabs can be burned, heated, rolled, and sheared to meet customer order requirements. This problem is an integral part of the day-to-day operations of steel plate manufacturing. A 0–1 integer programming formulation is presented and two heuristics, based on single-order formulations, are presented to quickly generate lower and upper bounds. The bounds are improved using Lagrangian relaxation and subgradient optimization, producing average optimality gaps of 2.12% on 17 real-world data sets. The upper bound improvements represent actual savings over the current solution method of 1.94%, or an average of about $230?000 over a 3-week period. An economic interpretation of the Lagrange multipliers is also discussed and shown to be useful for handling rush orders.     

Modelling of heat affected zone in cylindrical steel elements surfaced by welding

Computational models of a temperature field in cylindrical steel elements surfaced by the following methods: controlled pitch, spiral welding sequence and spiral welding sequence with swinging motion of the welding head are presented in the paper. The lateral surface of regenerated cylindrical object, subjected to the welding heat source, has been treated as a plane rolled on cylinder and temperature field of repeatedly surfaced plain massive body was solved. Temperature rises, caused by overlaying consecutive welding sequences and self-cooling of areas previously heated, were taken into consideration in the solution. The computations of the temperature field for continuous casting steel machine roll made of 13CrMo4 steel were carried out.     

Numerical solution to the optimal feedback control of continuous casting process

Using a semi-discrete model that describes the heat transfer of a continuous casting process of steel, this paper is addressed to an optimal control problem of the continuous casting process in the secondary cooling zone with water spray control. The approach is based on the Hamilton–Jacobi–Bellman equation satisfied by the value function. It is shown that the value function is the viscosity solution of the Hamilton–Jacobi–Bellman equation. The optimal feedback control is found numerically by solving the associated Hamilton–Jacobi–Bellman equation through a designed finite difference scheme. The validity of the optimality of the obtained control is experimented numerically through comparisons with different admissible controls. Detailed study of a low-carbon billet caster is presented.     

The use of linear approximation scheme for solving the Stefan problem

This paper deals with the linear approximation scheme to approximate a singular parabolic problem: the two-phase Stefan problem on a domain consisting of two components with imperfect contact. The results of some numerical experiments and comparisons are presented. The method was used to determine the temperature of steel in the process of continuous casting.     

A three-dimensional fluid flow model for puddle formation in the single-roll rapid solidification process

The single-roll rapid solidification process (SRRSP) is considered to be a process of perspective to produce a Fe-Si-B ribbon of amorphous microstructure and near net shape products such as thin strips of stainless steel. The condition of a melt puddle between the nozzle and rotating wheel in the single-roll rapid solidification process significantly affects the quality and dimensional uniformity of the products as well as the smoothness of the operation. The purpose of this study was to develop a three-dimensional fluid flow analysis system to model the formation of puddle and flow conditions of molten metal in the puddle for the single-roll rapid solidification processes which include the planar flow casting (PFC) process and the single-roll strip casting process. The model is based on a computational fluid dynamics technique called the SOLA-VOF scheme, which possesses the capability of treating transient fluid flow problems with the evolution of free boundaries. Furthermore, the SOLA-VOF scheme is extended from two dimensions to three dimensions. The simulated results reveal how the melt puddle is formed between the nozzle and the rotating substrate and its corresponding fluid flow behavior for the PFC process as well as the single-roll strip casting process. The test results also demonstrate that two-dimensional analysis cannot properly consider the actual flow condition in the puddle.     

Modeling of mold filling of Al gravity casting and validation with X-ray in-situ observation

In the mold filling simulation, element parameters including volume filled ratio, surface dimensionless distance, and surface filled ratio, were proposed to describe the shape and location of free surfaces in DFDM (Direct Finite Difference Method) elements. A model of the filling process was established, specially taking into account the mass, momentum and heat transfer in the vicinity of free surfaces. It was applied to an experimental AC4C (Al–7Si–0.4Mg) gravity casting. With a special X-ray apparatus, in-situ observation and record of actual mold filling process of the casting were carried out. The simulation results were validated and analyzed by comparing with the observation. The liquid flowing in the casting runner and ingate as well as the evolution of free surfaces were analyzed and discussed.     

Efficiency of a DC magnetic field used for braking the flow within a continuous casting mould

The continuous casting technology provides about 90 percent of the world steel production. The application of DC magnetic fields in form of so-called electromagnetic brakes is considered for an effective flow control with substantial capabilities to improve the product quality or to enhance the productivity of the process. The main effect of the DC magnetic field is supposed to result in a uniform reduction of the maximum velocities in the discharging jet from the submerged entry nozzle and to damp violent turbulent fluctuations. However, the electromagnetic braking of such highly turbulent and complex flows is complicated phenomenon and has not been understood fully until now. We present numerical and experimental investigations focusing on the fluid flow in the continuous casting mould under the influence of a transverse magnetic field. Numerical calculations were performed using the software package CFX with an implemented RANS-SST turbulence model. the non-isotropic nature of the MHD turbulence was taken into account by specific modifications of the turbulence model. Corresponding experimental investigations were carried out at the mock-up LIMMCAST at HZDR. The comparison between our numerical calculations and the experimental results display a very well agreement. An important outcome of this study is the feature that the magnetic field does not provide a continuous reduction of the velocity fluctuations at the nozzle port. (© 2011 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Influence of electromagnetic stirrer position on fluid flow and solidification in continuous casting mold

A computational study of the effect of stirrer position on fluid flow and solidification in a continuous casting billet mold with in-mold electromagnetic stirring has been carried out. The numerical investigation uses a full coupling method in which alternating magnetic field equations are solved simultaneously with the governing equations of fluid flow and heat transfer. An enthalpy-porosity technique is used for the solidification analysis while the magnetohydrodynamics technique is used for studying the fluid flow behavior under the electromagnetic field. The streamline, liquid fraction, and solid shell thickness at the mold wall have been predicted with and without EMS application at different positions along the length of the mold. Recirculation loops are seen to be formed above and below the stirrer position when fluid flow and electromagnetic field equations were solved, without incorporating the solidification model. Application of the solidification model interestingly resulted in the reduction of the size of the recirculation loops formed. The tangential component of velocity of the fluid near the solidification front, stirring intensity and the effective length of stirring below the stirrer decrease as the stirrer position is moved downwards. Significant changes in characteristics of solid shell formation like delay in initiation of solidification at the mold wall and formation of a gap in the re-solidified shell have been observed with change in stirrer position.     

Optimal Control of Continuous Casting by Nondifferentiable Multiobjective Optimization

A new version of an interactive NIMBUS method for nondifferentiable multiobjective optimization is described. It is based on the reference point idea and the classification of the objective functions. The original problem is transformed into a single objective form according to the classification information. NIMBUS has been designed especially to be able to handle complicated real-life problems in a user-friendly way.The NIMBUS method is used for solving an optimal control problem related to the continuous casting of steel. The main goal is to minimize the defects in the final product. Conflicting objective functions are constructed according to certain metallurgical criteria and some technological constraints. Due to the phase changes during the cooling process there exist discontinuities in the derivative of the temperature distribution. Thus, the problem is nondifferentiable.Like many real-life problems, the casting model is large and complicated and numerically demanding. NIMBUS provides an efficient way of handling the difficulties and, at the same time, aids the user in finding a satisficing solution. In the end, some numerical experiments are reported and compared with earlier results.