Use of Simulation Techniques for the Design and Process Control of Continuous Casting Machines

This article presents the latest solutions implemented by Concast AG in the field of process simulation and illustrates the use of finite element method (FEM) models for the engineering of continuous casters and for process control in continuous casting. The first application presented is the use of FEM models for the design of the new Integrated Mould concept, which combines the benefits of both tube- and plate moulds for bloom casters. Second, the Concast real-time solidification model is presented. The article describes this model and its use for controlling the secondary cooling as well as to control mechanical soft reduction (MSR) as function of the actual casting parameters like temperature, casting speed, cooling intensity, both during steady and transient times. Field results show that this model permits us to improve the internal quality of continuous-cast blooms compared to static soft reduction. Finally, the development of a modular program for the design of continuous casters is presented. This integrated program is based on FEM and CAD and permits a fast optimisation of the caster design variables by linking together geometry, solidification, and mechanical calculation of strand solidification, bulging, and support. This approach contributes to a faster and more effective definition of any continuous caster in the early phase of the project, which results in cost and time savings.