Real Time Model Based Spray Cooling Cont

This article presents a novel system for controlling secondary cooling water sprays in the continuous casting process of thin steel slabs, referred to as CONONLINE. The objective is to enhance temperature measurement reliability by utilizing a real-time numerical simulation model of heat transfer and solidification instead of traditional, unreliable temperature measurements. The one-dimensional finite-difference model, known as CON1D, has been adapted to predict slab temperature and solidification state in real-time, with updates provided by automation data gathered during operation. A decentralized controller configuration was developed based on a bank of proportional-integral controllers, which includes anti-windup mechanisms to maintain the desired shell surface-temperature profile. Additionally, a new set-point generation method was introduced to accommodate variations in measured mold heat flux. Results from example simulations demonstrate that the proposed system achieves significantly improved control over the shell surface-temperature profile, thereby suggesting a potential advancement in the quality of continuous casting processes. This innovative approach addresses the critical challenges in optimizing cooling processes to prevent defects in the produced slabs.