The vast experience of Primetals Technologies in the field of continuous casting directly leads to the age of digitalization. Expert systems, advanced simulations, and high-end measuring devices are among the new solutions that propel continuous casting to new heights.
Quality Expert
Quality Expert is a computer-aided quality-control system for all types of continuous casters. It is designed to determine the definitions necessary for quality-related process parameters, to track data during production, and to predict the quality of cast products so that potentially defective products can be separated.
It provides plant operators with online quality alerts and a preview of the quality of the casting strands in the machine. Quality Expert comes in two editions with either basic or comprehensive product-quality rating capabilities.
The online quality-control functions are configured in the Maintenance and Simulation System. The flexible rule editor enables end users to adapt or add quality rules without the support of specialized software engineers. Rule systems for predicting the quality of product-defect types (cleanliness, surface quality, inner quality) can be configured. The Quality Expert then evaluates quality rules online and displays the resulting quality rating. The quality previews are available for hot strands currently being cast and for products already cut, along with a root cause explanation of the quality rating. The knowledge-base component means that Quality Expert is easy to configure, enabling process engineers to react quickly to changing quality demands and production requirements. Quality Expert records quality-critical process data at high resolution as it is transmitted from the basic automation system and process computers. All tracked data and calculation results can be transferred from the Quality Expert’s production module to a solution called the Discovery system, which is dedicated to the long-term archiving and evaluation of tracked data in accordance with ISO 9001 standards. Quality Expert represents a milestone in improving quality control in continuous casting. Cost savings can be achieved by avoiding product inspection and conditioning activities, thereby minimizing material losses and handling costs.
Yield Expert
The aim of the Yield Expert is to minimize scrap and to optimize yield. It considers scrap portions, quality defects, weight restrictions, sample cuts, and width changes while producing the maximum number of scheduled products. Yield Expert optimizes product length or product weight whenever scrap sections need to be taken care of, thanks to advanced algorithms that determine the area that should be allocated as a scrap section. It also handles quality-related defects, and schedules mold-width adjustments to amend the casting process. Yield Expert’s optimization algorithms can easily be switched on or off via direct on-line control. One of Yield Expert’s strongest features is the ability to replay previously used cut-to-length optimization steps within actual production setups. Yield optimization has never been so easy, straightforward, and transparent.
Yield Expert minimizes scrap during production, optimizes the casting process, and handles quality-related defects.
Intermix Expert
The Intermix Expert for all types of continuous casting machines calculates the mixed-steel area and incompatible strand portions along the entire strand. The information gathered allows the Yield Expert to cut prime products before and after the incompatible section of the strand, so maximum prime-quality yield is ensured.
Steel mixing takes place not only in the tundish but also in the mold and upper parts of the strand. Mixing in these areas is evaluated by a mix-box-type submodel of the Intermix Expert, which makes it possible to calculate the chemical composition of the steel at any position along the cast strand. Based on the chemical composition of the steel, the Intermix Expert calculates whether the mixed steel zones can be used for the desired product application or if the steel has to be downgraded or even scrapped. Input parameters such as analysis, tundish weight, casting speeds, and dimensions of the strand are taken into account.
The computed results are visualized in the human machine interface. Graphs are displayed for single-analysis elements or combinations of multiple elements. Valuable information including volume concentration, mixed steel length, scrap length, and heat ranges on the strand are displayed on the screen. Configuration and simulation of the model are easily carried out in the Maintenance and Simulation System. Metallurgists can choose which chemical elements are used to determine the intermix for any steel grade. At the same time, Intermix Expert will provide them with precise information on the chemical analysis at any position on the cast slabs. The Intermix Expert’s powerful simulation environment allows the intermix of different steel grades to be accurately tested.
Equipment Expert
The Equipment Expert is designed to monitor the installed equipment of the caster and provide operators with valuable feedback about any maintenance work required. Equipment could include, for example, an entire segment, individual rolls, a mold, or mold plates. Equipment test reports, manuals, and instruction documents for equipment are viewed in the human machine interface. For every piece of equipment, lifetime or partial-lifetime criteria are defined. Such criteria might include the number of heats, casting time, casting length, tons, durations, or any other factors. The Equipment Expert collects these criteria for each piece of equipment and notifies operators when a lifetime criterion is due to be reached, in order to facilitate preventive maintenance.
