Germany, June 2011

New Sensor controls Solidification Process

CasterCrown®- TechnologyVGH Viktoria Garten Hüttenindustriebedarf AGBarmer Str. 1758332 SchwelmDeutschlandTel : +49-2336-4711-0Fax : +49-2336-4711-11web : www.vgh-ag.de

Overview of CasterCrown® - System

Definition of CasterCrown® - Sensor

The CasterCrown® - Sensor is a servo hydraulically positioned lifting beam with a strand guiding roll. A new feature is the possibility to measure exactly the position of the end of solidification.

Oszillation um ± 0,2 mm

Strand solidified:Low Damping

Strand with liquid core:High Damping

CasterCrown® Thermal TrackingCasterCrown® Solidification Model EP – Cooling Model

CasterCrown® Sensor

Measuring

Calculation

Operation

The CasterCrown® System

CasterCrown ® - Sensor

Calibration

Visualization / HMI / Navigator

References

CasterCrown® Reference List:

Salzgitter Flachstahl GmbH, Salzgitter, Germany

Continuous Casting Machine No. 1

Continuous Casting Machine No. 2

ArcelorMittal Gent (Sidmar), Belgium

Continuous Casting Machine No. 1

Continuous Casting Machine No. 2

ThyssenKrupp Nirosta, Bochum, Germany

Continuous Casting Machine

ArcelorMittal Eisenhüttenstadt, Eisenhüttenstadt, Germany

Continuous Casting Machine Strand 1

Continuous Casting Machine Strand 2

Deutsche Edelstahlwerke GmbH, Witten, Germany

Continuous Casting Machine Strand 1

Continuous Casting Machine Strand 2

The CasterCrown® System: CasterCrown® - Sensor

Inner Cross Beam

Roller

Outer Cross Beam

SMS- DemagSteel Plant

DanieliSteel Plant

PositionCasterCrown®

Recommended Area for

Solidification Point

0,5 m

The CasterCrown® System: CasterCrown® - Sensor

Example for a System with 1 Sensor

6 m

Process Data

CasterCrown®

Calibration

Process Control

The CasterCrown® System: Calculation

EP-Cooling Model

CasterCrown® - Measuring

Closed Loop

Process Data: Casting speed Mould cooling values Machine cooling values Spray cooling values Steel grade Tundish temperature

EP – Cooling Model Growth of Strand shell Surface Temperatures Shrinking of Strand Metallurgical Length

Process Control of: - Cooling / Solidification Length- Soft Reduction- Optimum Machine Taper

Solidification

CasterCrown® Closed Loop Calibration

Calibration:- Position of Crater End- Optimum Roller Gap- Machine’s Geometry

The CasterCrown® System: Calculation

CasterCrown® - Sensor

EP- Cooling Model: Surface Temperatures

Example on 16.08.2010 vg= 1,35 m/min

[m]

[°C]

Citation of the report of ArcelorMittal Maizières Research SA concerning the CasterCrown- System Sidmar (report of Karim CHERIF from 24th of May, 2011):

Crater end detection

CasterCrown model is calibrated with absorbed energy signal. Considering EP knowledge on the point of the absorbed energy signal corresponding to crater end passage, CasterCrown model matches well.

For  the same considerations of crater end passage detected by absorbed energy signal, the Dynasore model predicts a little shorter solid pool end position, and consequently predicts passage of crater end in front of the sensor few minutes later.

Slab surface temperature

Slab surface temperature has been operated on July and August 2010 by pyrometers implemented at exit of cooling zones of CC2 strand 4.

CasterCrown model matches well with measurements of slab surface temperature at steady states.

The CasterCrown® System: EP – Cooling Model

Solidification LengthCasting Speed “vc”

Casting width

PositionCasterCrown®

Sensor

Automatic Calibration of the EP - Cooling Model

[ m ] [ mm ] [ m/min ]

Incr

ease

of

vc

The CasterCrown® System: EP - Cooling Model

2. Mushy Zoneis entering

CasterCrown®:Calibration

3. Mushy Zoneunder

CasterCrown®

1. Solidified strand under

CasterCrown®,Oscillation starts

Solidification Length

PositionCasterCrown®

Sensor

Automatic Calibration of the EP - Cooling Model[ m ] [ m/min ]

The CasterCrown® System: EP - Cooling Model

EP- Cooling Model:- 0,03 m

Casting Speed “vc”

The CasterCrown® System: Operation / HMI / Navigator

CasterCrown® Sensor

Measuring

Calculation

Operation

CasterCrown ® Sensor

CasterCrown® Thermal TrackingCasterCrown® Solidification Model EP – Cooling Model

Calibration

Visualization / HMI / Navigator

700 °C

2PriorityOptimizedShrinking

Solidification Length

Surface Temperature

1,05Segregation Index

45,0 mm/min

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 mm/min

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm

3,6 mm/min 2,2 mm/min4,9 mm/min 4,1 mm/min

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 mm/min 0,0 mm/min

+1,80

12 %

23 %

65 %Navigator

Optimale Schrumpfung

Optimale Oberflächen-

tempera-tur

Betriebs-punkt

Maximale Gießgeschwindig- keitOptimized

ShrinkingSolidification

Length

3Priority 1Priority

31,35 m

34,50 m

2Priority

942 °COptimizedShrinking

Solidification Length

Surface Temperature

41 %

96 %

53 %

Opt. Surface Temperature

1,02Segregation Index

Point of Operation2,10 m/minVc,max =

0,95 m/minVcmin =

from

to

Navigato

r45,0 mm/min

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 mm/min

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm

3,6 mm/min 2,2 mm/min4,9 mm/min 4,1 mm/min

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 mm/min 0,0 mm/min

+1,80

12 %

23 %

65 %Navigator

The Navigator is an easy to use tool for Optimization of Quality and

Productivity in continuous casting.

It is based on the EP- Cooling model including the CasterCrown-

Sensor.

Setup of the Navigator

OptimizedShrinking

Solidification Length

3Priority Segregation Index 1Priority1,05

22,32 m

Opt. Surface Temperature

980 °C

2PriorityOptimizedShrinking

Solidification Length

Surface Temperature

43 % 100 % 88 %

0,95 m/minVc,min =

1,10 m/minVc,max =

Min.:

25,30 mMax.:

Solidification Length

3Priority 1Priority

27,7 m

Opt. Surface Temperature700 °C

2PriorityOptimizedShrinking

Solidification Length

Surface Temperature

23 % 98 % 99 %

1,6 m/minVc,max =

OptimizedShrinking

1,05Segregation Index

45,0 mm/min

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 mm/min

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm

3,6 mm/min 2,2 mm/min4,9 mm/min 4,1 mm/min

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 mm/min 0,0 mm/min

+1,80

12 %

23 %

65 %Navigator

Optimale Schrumpfung

Optimale Oberflächen-

tempera-tur

Betriebs-punkt

Maximale Gießgeschwindig-keitOptimized

ShrinkingSolidification

Length

3Priority 1Priority

22,82 m

25,30 m

2Priority

947 °COptimizedShrinking

Solidification Length

Surface Temperature

41 %

96 %

88 %

Opt. Surface Temperature

1,02Segregation Index

Point of Operation1,21 m/minVc,max =

0,95 m/minVc,min =

from

to

UnbendingZone

Solidification Length

3Priority 1Priority

27,7 m

Opt. Surface Temperature700 °C

2PriorityOptimizedShrinking

Solidification Length

Surface Temperature

23 % 98 % 99 %

1,6 m/minVc,max =

OptimizedShrinking

1,05Segregation Index

45,0 mm/min

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 mm/min

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm

3,6 mm/min 2,2 mm/min4,9 mm/min 4,1 mm/min

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 mm/min 0,0 mm/min

+1,80

12 %

23 %

65 %Navigator

Optimale Schrumpfung

Optimale Oberflächen-

tempera-tur

Betriebs-punkt

Maximale Gießgeschwindig-keitOptimized

ShrinkingSolidification

Length

3Priority 1Priority

22,82 m

25,30 m

2Priority

947 °COptimizedShrinking

Solidification Length

Surface Temperature

41 %

96 %

88 %

Opt. Surface Temperature

1,02Segregation Index

Point of Operation1,21 m/minVc,max =

0,95 m/minVc,min =

from

to

Vg= 1,1m/min

Vg= 1,4m/min

VSpraywater= 70%

VSpraywater= 65%

Solidification Length

3Priority 1Priority

27,7 m

Opt. Surface Temperature700 °C

2PriorityOptimizedShrinking

Solidification Length

Surface Temperature

23 % 98 % 99 %

1,6 m/minVc,max =

OptimizedShrinking

1,05Segregation Index

45,0 mm/min

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 mm/min

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm

3,6 mm/min 2,2 mm/min4,9 mm/min 4,1 mm/min

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 mm/min 0,0 mm/min

+1,80

12 %

23 %

65 %Navigator

Optimale Schrumpfung

Optimale Oberflächen-

tempera-tur

Betriebs-punkt

Maximale Gießgeschwindig-keitOptimized

ShrinkingSolidification

Length

3Priority 1Priority

22,82 m

25,30 m

2Priority

947 °COptimizedShrinking

Solidification Length

Surface Temperature

41 %

96 %

88 %

Opt. Surface Temperature

1,02Segregation Index

Point of Operation1,21 m/minVc,max =

0,95 m/minVc,min =

from

to

Solidification Length

Max Casting Speed

ThyssenKrupp Nirosta Germany

Examples for Operational Results

+ 10 %Output Stainless Steel

Grade 4016

DEW Witten, Germany

Examples for Operational Results

+ 15 %Output Stainless Steel

Grade 6587

Increasing Quality: Follow the natural Shrinking!

Distance from Mold Level

Strand Thickness

Bulging

Strand Thickness

End of Mould

Foot Rollers

End of Spray Cooling

End of Continuous Casting Machine

Natural Shrinking of Strand Thickness

Control: 1. Rate of Reduction [mm/m]

2. Range of Reduction [% of Solid Fraction]

Solidification Point solidus,

100 % Solid Fraction

Casting- direction

Increasing Quality: Control of Soft Reduction

Solidification Point liquidus,

0 % Solid Fraction

Beginn of Soft Reduction freely adjustable

End of Soft Reduction freely adjustable

e.g. 28 % Solid Fraction

e.g. 91 % Solid Fraction

Degree of deformation

freely adjustable

Increasing Quality: Control of Soft Reduction

Problem: Bad central segregationcontinuous central band, mainly martensite

Increasing Quality: Control of Soft Reduction

Central segregation was almost continuous:

Result with Soft Reduction controlled by CasterCrown®:- Segregated spots have

almost all disappeared!- Less central segregation,

only fewer isolated islandsremain!

Measuring of Overloads

Overload of Rollers

700 °C

2PriorityOptimizedShrinking

Solidification Length

Surface Temperature

1,05Segregation Index

45,0 mm/min

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 mm/min

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm

3,6 mm/min 2,2 mm/min4,9 mm/min 4,1 mm/min

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 mm/min 0,0 mm/min

+1,80

12 %

23 %

65 %Navigator

Optimale Schrumpfung

Optimale Oberflächen-

tempera-tur

Betriebs-punkt

Maximale Gießgeschwindig-keitOptimized

ShrinkingSolidification

Length

3Priority 1Priority

31,35 m

34,50 m

2Priority

942 °COptimizedShrinking

Solidification Length

Surface Temperature

41 %

96 %

53 %

Opt. Surface Temperature

1,02Segregation Index

Point of Operation2,10 m/minVc,max =

0,95 m/minVcmin =

from

to

45,0 m m /m in

Opt. sollwaarde stolpunt:

Opt. Gietsnelheid:

+2,0722,5 m m /m in

1217 ° C226,2 mm

227,0 mm

1178 ° C225,9 mm

1114 ° C225,4 mm

1129 ° C225,5 mm

1128 ° C225,5 mm

1151 ° C225,6 mm

1110 ° C225,2 mm

1161 ° C225,6 mm

1128 ° C225,4 mm3,6 m m /m in 2,2 m m /m in4,9 m m /m in 4,1 m m /m in

1149 ° C225,4 mm

1131 ° C225,2 mm

1113 ° C225,0 mm

1128 ° C225,1 mm

1096 ° C224,9 mm

1048° C224,5 mm

0,0 m m /m in 0,0 m m /m in

+1,80

12 %

23 %

65 %Navigator

Strand Shell Growth Surface Temperatures

Strand Shrinkingcalibrated by CasterCrown® - Sensor

Benefits

CasterCrown®- Basic

CasterCrown®-Position ofCrater End

CasterCrown®-Optimum

Roller Gap

Calibration

Calibration

Length ofSolidification

CasterCrown®

Simulation

EP- Cooling Model

- Strand Shell Growth

- Surface Temperatures

- Strand Shell Shrinking

ActualValues

Actual Value

Soft ReductionOptimum Control of Soft Reduction

Real time Control ofSolidification Length

Increase of Productivity

typically + 10%

For Soft Reduction grades: Improvement of

inner Quality Less Downgrading Less damage of machine

Minimization of Cracks Increase of Quality Less Downgrading

- Control and Optimization of cooling and casting speed

- Control or Correction ofMachine Taper

Minimized maintenance cost Reduction of Shut Down Time

Measuring

CasterCrown®-Overload

Monitoring Minimization of Overloads

CalibrationCasterCrown®-Surface

Temperatures

Detection ofOverloads / Alarming

Calibration by E

nergy Balance

http://www.vgh-ag.com