Caster Crown PPT Ver 1.01

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CasterCrown
Features of
The System:
- Sensor - Cooling Model - Operation / Navigator
Operational Results Quality Summary System Tests
CasterCrown- Technology
New Sensor controls Solidification Process
Germany, June 2011
ENGINEERING PARTNER GMBH
VGH Viktoria Garten Httenindustriebedarf AG Barmer Str. 17 58332 Schwelm Deutschland Tel : +49-2336-4711-0 Fax : +49-2336-4711-11 web : www.vgh-ag.de Page 1
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Overview of CasterCrown System
CasterCrown
Features of
The System:
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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.
CasterCrown
Features of
The System:
Oszillation um 0,2 mm
Operational Results
Strand solidified: Summary Low Damping

Quality System Tests
Strand with liquid core: High Damping
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The CasterCrown System
CasterCrown
Features of
Opera tion
The System:
Visualization / HMI / Navigator
Calcul ation Measu ring
C asterC rown Cooling Tracking asterC rown Thermal Model EP Solidification Model
Calibration
C asterC rown Sensor - Sensor CasterCrow
n
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References CasterCrown Reference List:

Salzgitter Flachstahl GmbH, Salzgitter, Germany Continuous Casting Machine No. 1 Continuous Casting Machine No. 2
CasterCrown Continuous
Features of ArcelorMittal
Gent (Sidmar), Belgium Casting Machine No. 1 The System: Continuous Casting Machine No. 2
- Sensor ThyssenKrupp Nirosta, Bochum, Germany - Cooling Model - Operation / Continuous Casting Machine Navigator
ArcelorMittal Operational Results

Quality Summary
Eisenhttenstadt, Eisenhttenstadt, Germany Continuous Casting Machine Strand 1 Continuous Casting Machine Strand 2 Edelstahlwerke GmbH, Witten, Germany Continuous Casting Machine Strand 1 Continuous Casting Machine Strand 2
Deutsche System Tests
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The CasterCrown System: CasterCrown Sensor
CasterCrown
Features of
The System:
Outer Cross Beam
Inner Cross Beam Roll er

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CasterCrown
Features of
The System:
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SMS- Demag Steel Plant
CasterCrown
Features of
The System:
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CasterCrown
Features of
The System:
Danieli Steel Plant

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The CasterCrown System: CasterCrown Sensor Example for a System with 1 Sensor
Features of
CasterCrown
The System:
Position CasterCrown
Recommended Area for Solidification Point
6m 0,5 m
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CasterCrown
Features of
The CasterCrown System: Calculation Process Data CasterCrown Calibration EP-Cooling Model
The System:
Closed Loop
CasterCrown - Measuring
Process Control
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The CasterCrown System: Calculation

Process Data:

CasterCrown
Features of
Casting speed Mould cooling values Machine cooling values Spray cooling values Steel grade Tundish temperature
CasterCrown
Closed Loop Calibration Calibration:
-
The System:
EP Cooling Model

Growth of Strand shell Surface Temperatures Shrinking of Strand Metallurgical Length
Operational Results Quality Summary System Tests Process Control of: Cooling / Solidification Length Soft Reduction Optimum Machine Taper
Position of Crater End Optimum Roller Gap Machines Geometry
Solidification
CasterCrown - Sensor
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EP- Cooling Model: Surface Temperatures

Example on 16.08.2010
[C]
vg= 1,35 m/min
CasterCrown
Features of
The System:
[m]
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The CasterCrown System: EP Cooling Model
Citation of the report of ArcelorMittal Maizires 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.
CasterCrown
Features of
The System:
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The CasterCrown System: EP - Cooling Model Automatic Calibration of the EP - Cooling

[ m ] [ mm ]
Model
[ m/min ]
CasterCrown
Features of
Casting Speed vc
Solidification Length
Position CasterCrown Sensor
The System:
In cr e a s e of vc
Operational Results Quality Casting width Summary Solidified strand 1. System Tests under CasterCrown, Oscillation starts
3. Mushy
Zone under CasterCrown
2. Mushy
Zone is entering CasterCrown : Calibration
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The CasterCrown System: EP - Cooling Model Automatic Calibration of the EP - Cooling

[ m ] [ m/min ]
Model
CasterCrown
Features of
Position CasterCrown Sensor
The System:
Solidification Length
Operational Results Quality Summary System Tests Casting Speed vc
EP- Cooling Model: - 0,03 m
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The CasterCrown System: Operation / HMI / Navigator
CasterCrown
Features of
Opera tion
The System:
Operational Results Quality Summary
Formatvorlage des Untertitelmasters durch Klicken bearbeiten Visualization / HMI /

Navigator
System Tests
Calcul ation Measu ring
C asterC rown Thermal Tracking asterC rownEP Cooling Model Solidification Model
Calibration
C asterC rown Sensor Sensor CasterCrow n

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Segregation Index
4 ,0 mm/min 5 27 m 2 ,0 m
1,05
Segregation Index
Priority 3 Optimale Schrumpfung

Opt. Gietsnelheid:
+ ,0 2 7 + ,8 1 0
65 Optimized% Shrinking
Navigator
Priority 1,02 Maximale Giegeschwindig-1

keit 12 % Solidification Length
CasterCrown
Features of
2 ,5 mm/min 2
The System:
- Sensor 1 1 C 27 - Cooling226,2mm Model - Operation / C Navigator 1178mm 25 2 ,9
Vcmin = Vc,max =
0, 95 2, 10
m/mi n m/mi n
ato vig Na r
Opt. Surface Temperature
23 %
41 %
from to
31,3 5 34,5 0
m m
Point of Operation Betriebspunkt
1 1 C 14
25 m 2 ,4 m
Opt. sollwaarde stolpunt:
96 %
53 %
1 29 C 1
25 m 2 ,5 m
1 2 C 18
25 m 2 ,5 m
700 C
1 5 C 11
25 m 2 ,6 m
Optimale 94 Oberflchentempera2 C Priority 2 tur Optimized
1 6 C 11
25 m 2 ,6 m
Priority
2
11 0C 1
25 m 2 ,2 m
Shrinking
44, mm/ i 4 mn 4 44, m 4 m 44, mm/ i 4 mn O p. G et snel ei d: t i h +4 , 44 1 % 1
Na iga v tor
1 % 1
+4 , 44
444 C 4 444, m 4 m
4444 C 444, m m 4
444 C 444 , mm 4
O pt . sol w aard st ol punt : l e
1 % 1
444 C 4 444, mm 4
444 4C 444, m 4 m
Solidification Surface Length Temperature

1 2 C 18
25 m 2 ,1 m 2 mm/min ,2
Optimized Shrinking
4444 C 444, m 4 m
444 C 4 444 , m 4 m
4444 C 44, 4m 4 m 4, 4mm/ i n m
4444 C 44 44m , m
4444 C 444, m 4 m 4, 4mm/ i m n
444 C 4 4444 C 4444 C 4 444 C 4 44 C 4 444, m 4 m 444 4m , m 444, mm 4 4 4, 4m m 444, m 4 m 4, mm/ i 4 mn 4, m/ i 4 mn 4, 4m/ i n m 4, 4m/ i n m
1 2 C 18
25 m 2 ,4 m 3 mm/min ,6
1 4 C 19
25 m 2 ,4 m 4 mm/min ,9
1 3 C 11
25 m 2 ,2 m
1 3 C 11
25 m 2 ,0 m
1 9 C 06
24 m 2 ,9 m 0 mm/min ,0
1 48C 0
24 m 2 ,5 m 0 mm/min ,0
4 mm/min ,1
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Setup of the 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-
CasterCrown
Features of
Sensor.
Priority Optimized Shrinking
3
Segregation Index
1,05
Priority
The System:
Solidification Length Min.: Max.: 22,3 m 2 25,3 m 0
Operational Results Vc,min = 0,9 5 Summary Vc,max = 1,1 System Tests 0 Quality m/min m/min
43 %
100 %
88 %
Opt. Surface Temperature 980 C Priority

ENGINEERING PARTNER GMBH 2
Optimized Shrinking

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Priority
4 ,0 m /m 5 m in 27 m 2 ,0 m
Segregation Index 1,05

Opt. Gietsnelheid: 65 Optimized %
Priority
Optimized Shrinking
+ ,0 2 7 + ,8 1 0
Shrinking
CasterCrown
Features of
2 ,5 mm/m 2 in
Priority 1 Maximale GiegeschwindigSegregation Index 1,02 Solidification Navigator keit 12 % Solidification Length Length 27,7 m from 22,82 m
to
25,30 m
The System:
- Sensor 1217 C Vc,max = 1,6 26 m 2 ,2 m - Cooling Model - Operation / C Navigator 1178mm 25 2 ,9
Vc,min = 0,95 m/min
m/min
Vc,max = 1,21 m/min
1 1 C 14 Formatvorlage des Untertitelmasters durch Klicken bearbeiten

25 m 2 ,4 m
23 % Opt. Surface Temperature

Optimale 947 C OberflchentemperaPriority 2 tur
23 %
98 %
Optimized Shrinking
41 %
96 %
99 %
88 %
1 2 C 19
25 m 2 ,5 m
1 2 C 18
25 m 2 ,5 m
System Tests
1 5 C 11
Unbending Priority 25 m 2 ,6 m Zone 1 6 C 11 1 2 C 18

25 m 2 ,6 m 22 ,4m 5 m
Opt. Surface Temperature 700 C

2
1 1 C 10
25 m 2 ,2 m
Optimized Shrinking
1 4 C 19
25 m 2 ,4 m 4 m /min ,9 m

1 2 C 18
2 5,1m 2 m 2 m /m ,2 m in
1 3 C 11
22 ,2m 5 m
1 1 C 13
25 m 2 ,0 m
1 9 C 06
24 m 2 ,9 m 0 mm in ,0 /m
1 8C 04
24 m 2 ,5 m 0 m /min ,0 m
3 mm in ,6 /m
4 mm/m ,1 in
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Priority
4 m /m 5,0 m in 27 m 2 ,0 m

Priority
Optimized Shrinking
CasterCrown
Features of
2 ,5 m /min 2 m
VSpraywater= 70%+1,80 Vg= 1,1m/min m/min
+ ,0 2 7
Shrinking
to
25,30 m
The System:
Vc,min = 0,95 m/min Vc,max = 1,21 m/min

2 ,4m 25 m
1 2 C 19
25 m 2 ,5 m
System Tests
VSpraywater= Temperature Opt. Surface 1 2 C 1 8 65% 700 C

25 m 2 ,5 m

23 %
98 %
Optimized Shrinking
41 %
96 %
99 %
88 %
1 5 C 11
25 m 2 ,6 m
Vg= 1,4m/min
1 6 C 11
25 m 2 ,6 m
Priority
1 2 C 18
25 m 2 ,4 m 3 mm in ,6 /m
Optimized Shrinking
1 4 C 19
25 m 2 ,4 m 4 m /m ,9 m in

1 2 C 18
25 m 2 ,1 m 2 m /m ,2 m in
1 1 C 10
25 m 2 ,2 m
1 3 C 11
25 m 2 ,2 m
1 1 C 13
25 m 2 ,0 m
1 9 C 06
24 m 2 ,9 m 0,0m /min m
14 0 8C
24 m 2 ,5 m 0 m /min ,0 m
4 m /min ,1 m
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Solidification Length Max Casting Speed

Priority
3

Priority
4 ,0 m /m 5 m in 27 m 2 ,0 m
Optimized Shrinking
+ ,0 2 7 + ,8 1 0
Shrinking
CasterCrown
Features of
2 ,5 mm/m 2 in
to
25,30 m
The System:
Vc,min = 0,95 m/min
m/min
Vc,max = 1,21 m/min

25 m 2 ,4 m

23 %
98 %
Optimized Shrinking
41 %
96 %
99 %
88 %
1 2 C 19
25 m 2 ,5 m
1 2 C 18
25 m 2 ,5 m
System Tests
Opt. Surface Temperature 700 C

1 5 C 11
25 m 2 ,6 m
1 6 C 11
25 m 2 ,6 m
Priority
1 2 C 18
22 ,4m 5 m 3 mm in ,6 /m
Optimized Shrinking
1 4 C 19
25 m 2 ,4 m 4 m /min ,9 m

1 2 C 18
2 5,1m 2 m 2 m /m ,2 m in
1 1 C 10
25 m 2 ,2 m
1 3 C 11
22 ,2m 5 m
1 1 C 13
25 m 2 ,0 m
1 9 C 06
24 m 2 ,9 m 0 mm in ,0 /m
1 8C 04
24 m 2 ,5 m 0 m /min ,0 m
4 mm/m ,1 in
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Examples for Operational Results
ThyssenKrupp Nirosta Germany
CasterCrown
Features of
1 0
The System:
O u t p u t S t ai n le s s S t e el G r a
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Examples for Operational Results
DEW Witten, Germany
CasterCrown
Features of
1 5
The System:
O u t p u t S t ai n le s s S t e el G r a
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Increasing Quality: Follow the natural Shrinking!

Strand Thickness Strand Thickness Bulgi ng
CasterCrown
Features of
The System:
Foot Rollers
End of Continuous Casting Machine
Natural Shrinking of Strand Thickness
End of Mould End of Spray Cooling Distance from Mold Level
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Increasing Quality: Control of Soft Reduction
Control: 1. Rate of Reduction [mm/m] 2. Range of Reduction [% of Solid Fraction]
CasterCrown
Features of
Beginn of Soft Reduction

freely adjustable
End of Soft Reduction

freely adjustable
The System:
- Sensor - Cooling Model - Operation / Navigator Solidification Point liquidus, 0 % Solid Fraction Degree of deformation freely adjustable Solidification Point solidus, 100 % Solid Fraction

Castingdirection
e.g. 28 % Solid Fraction
e.g. 91 % Solid Fraction

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Increasing Quality: Control of Soft Reduction Problem: Bad central segregation

continuous central band, mainly martensite
CasterCrown
Features of
The System:
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Increasing Quality: Control of Soft Reduction

Central segregation was almost continuous:
CasterCrown
Features of
The System:
Result with Soft Reduction controlled by CasterCrown: - Segregated spots have almost all disappeared! - Less central segregation, only fewer isolated islands remain!
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Measuring of Overloads
CasterCrown
Features of
The System:
Overload of Rollers
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4 ,0 m /m 5 m in 27 m 2 ,0 m
Shrinking calibrated by CasterCrown - Sensor + ,0 2 7

+ ,8 1 0 Vcmin =
4 ,0 mm in 5 /m
Strand Shell Growth Segregation Index 1,05 Surface Temperatures Segregation Index Priority 3 Optimale Schrumpfung Navigator Strand Shrinking 65 Opt. Gietsnelheid: Optimized %
Priority 1 Maximale Giegeschwindig1,02

keit 12 % Solidification Length from 31,35 m
CasterCrown
Features of
2 ,5 mm in 2 /m
to
34,50 m
The System:
0,95 m/min
65 %
Navigator
- Sensor 1217C 27 m 2 ,0 m - Cooling 226,2mm 22,5 mm/min Model - Operation / C Navigator 1178mm 25 2 ,9
Opt. Gietsnelheid:
Vc,max = 2,10 m/min + ,0 2 7 + ,8 1 0

25 m 2 ,4 m
1 1 C 27 1 2 6,2m 122 Cm 9
25 m 2 ,5 m
Opt. Surface Temperature
23 %
41 %
96 %
53 %
System Tests
1 2 C 18 1 7 225,5m 1 8 C m
25 m 2 ,9 m
700 C
1 5 C 11
25 m 2 ,6 m
1 1 C 14
25 m 2 ,4 m
1 6 C 11
25 m 2 ,6 m
Priority
1 8C 12
25 m 2 ,4 m 3 m /m ,6 m in
Optimized Shrinking
1 1 C 10
25 m 2 ,2 m

1 2 C 18
25 m 2 ,1 m 2 mm in ,2 /m
Optimized Shrinking
1 4 C 19
25 m 2 ,4 m 4 m /m ,9 m in
1 3 C 11
25 m 2 ,2 m
1 1 C 13
25 m 2 ,0 m
1 9 C 06
24 m 2 ,9 m 0 mm/m ,0 in
14 0 8C
24 m 2 ,5 m 0 m /m ,0 m in
4 m /m ,1 m in
23 %
1 2 C 19
25 m 2 ,5 m
1 28 C 1
25 m 2 ,5 m
1 5 C 11
25 m 2 ,6 m
1 6 C 11
25 m 2 ,6 m
1 2 C 18
25 m 2 ,4 m 3 m /m ,6 m in
1 1 C 10
25 m 2 ,2 m
11 9C 4
25 m 2 ,4 m 4 mm in ,9 /m
1 3 C 11
25 m 2 ,2 m
1 1 C 13
25 m 2 ,0 m
1 2 C 18
25 m 2 ,1 m
1 0
4 m /min ,1 m
2 mm in ,2 /m
Page 30mm/ 0 ,0
2 2
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Measuring
CasterCrownBasic
CasterCrown Simulation
R e a l Actual ti Value m e C O o Soft Reduction p n ti tr m o u lm o fC S -oC EP- Cooling Model o o n li n tr - Strand Shell Growth d tr o if o - Surface l iol Temperatures ca f - Strand Shell an S Shrinking ti d o o ft nO R Lp e e ti d nM Detection of um Overloads / Alarming gii c ttin z hia o m nti io z
Length of Solidification
Benefits
CasterCrown- C Position of Crater End ali
Increase of Productivity typically + 10%
CasterCrown
Features of
br ati on
The System:
C ali br ati on by E
CasterCrownOptimum Roller Gap
For Soft Reduction grades:
Improvement of inner Quality Less Downgrading Less damage of machine
Operational Results
B
C ali Quality br CasterCrown- ati C Summary Surface on Temperatures ali System Tests br ati on
Act ual Val ue s
ne rg y
al an ce
Minimization of Cracks Increase of Quality Less Downgrading
M on ito rin g ENGINEERING PARTNER GMBH

CasterCrownOverload
Minimized maintenance cost Reduction of Shut Down Time

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CasterCrown
Features of
The System:
http://www.vgh-ag.com
Page 32

Caster Crown PPT Ver 1.01

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C asterC rown

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

Overview of CasterCrown System

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

Definition of CasterCrown Sensor

Strand solidified: Summary Low Damping

Strand with liquid core: High Damping

ENGINEERING PARTNER GMBH

The CasterCrown System

Operational Results Quality Summary System Tests

Visualization / HMI / Navigator

Calcul ation Measu ring

C asterC rown Sensor - Sensor CasterCrow

ENGINEERING PARTNER GMBH

References CasterCrown Reference List:

ArcelorMittal Operational Results

Deutsche System Tests

ENGINEERING PARTNER GMBH

The CasterCrown System: CasterCrown Sensor

Outer Cross Beam

Operational Results Quality Summary System Tests

Inner Cross Beam Roll er

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

SMS- Demag Steel Plant

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

Operational Results Quality Summary System Tests

Danieli Steel Plant

Operational Results Quality Summary System Tests

Recommended Area for Solidification Point

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

The CasterCrown System: Calculation

Growth of Strand shell Surface Temperatures Shrinking of Strand Metallurgical Length

Position of Crater End Optimum Roller Gap Machines Geometry

ENGINEERING PARTNER GMBH

EP- Cooling Model: Surface Temperatures

vg= 1,35 m/min

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

The CasterCrown System: EP Cooling Model

Operational Results Quality Summary System Tests

ENGINEERING PARTNER GMBH

The CasterCrown System: EP - Cooling Model Automatic Calibration of the EP - Cooling

Position CasterCrown Sensor

ENGINEERING PARTNER GMBH

The CasterCrown System: EP - Cooling Model Automatic Calibration of the EP - Cooling

Position CasterCrown Sensor

Operational Results Quality Summary System Tests Casting Speed vc

EP- Cooling Model: - 0,03 m

ENGINEERING PARTNER GMBH

The CasterCrown System: Operation / HMI / Navigator

Operational Results Quality Summary

Formatvorlage des Untertitelmasters durch Klicken bearbeiten Visualization / HMI /

Calcul ation Measu ring

C asterC rown Sensor Sensor CasterCrow n

ENGINEERING PARTNER GMBH

Priority 3 Optimale Schrumpfung

Priority 1,02 Maximale Giegeschwindig-1

Point of Operation Betriebspunkt