The thesis deals with optimization of the continuous slab casting process. The thesis summarizes the basic analytical and empirical findings concerning to the solidification process, the numerical modeling and the selected optimization techniques. Physical conditions and factors that affect the quality of steel including their relationships are also described. The basis of the solution strategy is the original numerical model of the temperature field in its off-line version. The numerical model was verified by the real historical data. The optimization part is based on the fuzzy logic implemented above the numerical model. The optimization algorithm is used for the optimal control of the casting process. The universal usage of the optimization model is demonstrated on several cases, e.g. the finding of optimal casting parameters that ensure the high quality of products, the optimal reactions on breakdown situations, the determination of an optimal relationship between casting parameters, etc. Based on optimization results, the suitable caster modification to increase the surface temperature at the unbending point was proposed. The whole concept of the numerical and optimization model is general and it can be applied to arbitrary slab or billet continuous casting.

Foram tomadas amostras de aço líquido referentes a três grupos de aço, a saber: (I) aços baixo-carbono (0,02 %C 0,08), acalmados ao alumínio; (II) aços peritéticos (0,09 %C 0,15), acalmados ao alumínio e silício; (III) aços ultrabaixo carbono ( C<35 ppm), acalmados ao alumínio.Os aços foram produzidos em aciaria do tipo LD e foram, a seguir, tratados em equipamentos de refino secundário, adequados a cada um dos casos.As amostras forma colhidas no distribuidor de uma máquina de lingotamento contínuo de placas, segundo critério que minimiza a possibilidade da ocorrência de interferências que pudessem mascarar o resultado do tratamento de refino secundário tais como re-oxidação do aço e coleta simultânea de escória. As amostras foram submetidas à análise de inclusões utilizando-se técnicas de microscopia óptica, microscopia eletrônica e micro-análise. Foi possível caracterizar as inclusões presentes em cada tipo de aço segundo a morfologia, o tamanho, a quantidade e a composição química. / Non-metallic inclusions in liquid samples of (I) low-carbon aluminium killed steel (0,02wpct C 0,08wpct), (II) peritetic aluminium and silicon killed steel (0,09wpct C 0,15wpct); (III) extra-low-carbon, aluminium killed steel (C<35 ppm) were taken from the tundish distributor of a continuous casting caster for steel plates according to a procedure that minimizes re-oxidation of steel and/or pick up of liquid slag. The samples were inspected through the following microstructural techniques: optical microscopy, electronic microscopy, and electron microprobe. Were possible to feature present inclusion in each kind of steel according to morphology, size, amout and chemical composition.

Un système est souvent caractérisé par plusieurs modes de fonctionnement, chacun pouvant alors être décrit par un modèle qui lui est propre. Dans le cas où la commutation entre les modes de fonctionnement résulte d'un processus inconnu (un défaut, un changement de condition,...), il est difficile de manipuler ces systèmes et d'appliquer les commandes appropriées. Cette thèse traite du problème de la détection du changement de mode d'un système. A partir d'un système partiellement supervisé (connaissance du nombre de mode de fonctionnement du système ainsi que de la structure du modèle représentant chaque mode), une méthode est développée pour détecter le mode de fonctionnement actif du système à chaque instant. Pour cela, l'analyse du gradient des résidus obtenu par la multiplication des modèles locaux entre-eux, permet de caractériser le mode de fonctionnement. Une application de cette méthode est réalisée sur des données simulées et réelles de coulée continue de l'acier, afin de détecter un phénomène particulier : le collage. Finalement, une méthode par rejet de mode est mise en place sur des données réelles thermiques dans le même but (la détection des collages en lingotière de coulée continue) / Most of time a system is characterized by few operating modes, each of them could be describe by a model. In the case of the commutation between each operating mode is due to unknown process (fault, changing in condition,) it could be difficult to operate with this system and used the appropriate commands. With a partially supervised system (knowing of number of operating mode and model structure that represent each mode), a method is developed to detect the active operating mode at each time. Indeed, the analyses of the residual gradient, that obtain by product each local model together, permit to characterize the operating mode. Application of this method is presented with simulated data and industrial data of continuous casting to detect a particular phenomenon: the sticker. Finally, a rejection mode method is used on industrial thermal data in the same aim (detection of stickers in continuous casting)

<p>The present dissertation describes part of the efforts directed towards the development of computational tools to support process modeling. This work is also a further development of the Thermoslag software developed in the Division of Materials Process Science, KTH.</p><p>The essential parts of the thesis are</p><p>a) development of a semi-empirical model for the estimation of the molar volumes/densities of multicomponent slags with a view to incorporate the same in the model for viscosities and</p><p>b) further development of the viscosity model for application towards fluorid- containing slags, as for example, mould flux slags.</p><p>The model for the estimation of molar volume is based on a correlation between the relative integral molar volume of a slag system and the relative integral molar enthalpies of mixing of the same system. The integral molar enthalpies of the relevant systems could be evaluated from the Gibbs energy data available in the Thermoslag software. The binary parameters were evaluated from experimental measurements of the molar volumes. Satisfactory correlations were obtained in the case of the binary silicate and aluminate systems. The model was extended to ternary and multi component systems by computing the molar volumes using the binary parameters. The model predictions showed agreements with the molar volume data available in literature. The model was used to estimate the molar volumes of industrial slags as well as to trace the trends in molar volume due to compositional variations. The advantage of the present approach is that it would enable prediction of molar volumes of slags that are compatible with the thermodynamic data available.</p><p>With a view to extend the existing model for viscosities to F--containing slags, the viscosities of mould flux slags for continues casting in steel production have been investigated in the present work. The measurements were carried out utilizing the rotating cylinder method. Seven mould fluxes used in the Swedish steel industry and the impact of Al₂O₃pick up by mould flux slags on viscosities were included in the study. The results showed that even relatively small additions of Al₂O₃ are related with a significant increase in viscosity</p>

Submitted by Ronildo Prado (ronisp@ufscar.br) on 2017-08-23T14:10:16Z No. of bitstreams: 1 DissPICC.pdf: 9243099 bytes, checksum: d5c4984be722eda91236fbec51d566f6 (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-08-23T14:10:24Z (GMT) No. of bitstreams: 1 DissPICC.pdf: 9243099 bytes, checksum: d5c4984be722eda91236fbec51d566f6 (MD5) / Approved for entry into archive by Ronildo Prado (ronisp@ufscar.br) on 2017-08-23T14:10:29Z (GMT) No. of bitstreams: 1 DissPICC.pdf: 9243099 bytes, checksum: d5c4984be722eda91236fbec51d566f6 (MD5) / Made available in DSpace on 2017-08-23T14:10:35Z (GMT). No. of bitstreams: 1 DissPICC.pdf: 9243099 bytes, checksum: d5c4984be722eda91236fbec51d566f6 (MD5) Previous issue date: 2017-02-24 / Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES) / New materials from cellulose have been developed, such as cellulose nanocrystals (CNC) and cellulose nanofibrils (CNF). Different morphologies of the cellulose can lead to the formation of films with different thermal, mechanical and optical properties in relation to conventional cellulose films. The objective of this work was to evaluate the effect of different dimensional scales of cellulose, micro and nanometric, on the production of cellulose films from two vegetable species and their thermal, mechanical, morphological and optical properties. Eucalyptus fibers and pineapple leave fiber (curauá) (PALF) were used as cellulosic fibers for this study. The films of eucalyptus and pineapple cellulosic fibers were prepared by filtration and casting, and the CNC and CNF films were obtained by continuous casting. The CNC and CNF films showed mechanical tensile strength in the order of 9 to 35 MPa higher than the films of cellulose fibers, regardless of the origin of the fiber. The continuous casting process produced CNC and CNF films that presented different mechanical resistance in the longitudinal direction of the process with respect to the transverse direction. This behavior may be related to how hydrogen bonds and mechanical anchorages occur between nanofibers. The thermal stability of the nanocellulose films was lower in the order of 20 to 150 ºC than in the films of fibers due to the routes of obtaining the CNC and CNF. Nanofiber films presented lower opacity in the order of 3 to 60% lower than the films of fibers due to the diameter of the nanocelluloses. Curauá fibers had the highest crystallinity index (Ic) reaching 87%. It is concluded that the properties studied were influenced by the type of nanocellulose (CNC or CNF), the origin of the cellulose (eucalyptus or pineapple), and the micro and nanometric scale of the fibers. / Novos materiais a partir da celulose tem sido obtidos, como os nanocristais de celulose (CNC) e as nanofibrilas de celulose (CNF). Diferentes morfologias da celulose podem levar a formação de filmes com propriedades térmicas, mecânicas e ópticas diferentes de filmes de celulose convencional. O objetivo deste trabalho foi avaliar o efeito de diferentes morfologias de fibras de celulose, micro e nanométricas, na obtenção de filmes - provenientes de duas espécies vegetais – e em suas propriedades térmicas, mecânicas, ópticas e morfológicas. Utilizou-se como fibras celulósicas para este estudo as fibras de eucalipto e fibras de folhas de abacaxi (curauá) (PALF). Os filmes de fibras celulósicas de eucalipto e de abacaxi foram confeccionados por filtragem e casting, e os filmes de CNC e CNF foram obtidos por continuous casting. Os filmes de CNC e CNF apresentaram resistência mecânica à tração, na ordem de 9 a 35 MPa superior aos filmes de fibras de celulose, independente da origem da fibra. O processamento por continuous casting produziu filmes de CNC e CNF que apresentaram resistência mecânica diferente no sentido longitudinal ao processo com relação ao sentido transversal. Este comportamento pode estar relacionado de que forma ocorrem às ligações de hidrogênio e os emaranhamentos mecânicos entre as nanofibras. A estabilidade térmica dos filmes de nanofibra foi menor na ordem de 20 a 150 ºC do que aos filmes de fibras devido às rotas de obtenção das CNC e CNF. Os filmes de nanofibra apresentaram menor opacidade, na ordem de 3 a 60% inferior, que os filmes de fibras devido ao diâmetro das nanofibras. As fibras de curauá apresentaram o maior índice cristalinidade (Ic) chegando a 87%. Conclui-se que a propriedades estudadas foram influenciadas pelo tipo de nanofibra (CNC ou CNF), pela origem da celulose (eucalipto ou abacaxi), e pela escala micro e nanométrica das fibras.

Foram tomadas amostras de aço líquido referentes a três grupos de aço, a saber: (I) aços baixo-carbono (0,02 %C 0,08), acalmados ao alumínio; (II) aços peritéticos (0,09 %C 0,15), acalmados ao alumínio e silício; (III) aços ultrabaixo carbono ( C<35 ppm), acalmados ao alumínio.Os aços foram produzidos em aciaria do tipo LD e foram, a seguir, tratados em equipamentos de refino secundário, adequados a cada um dos casos.As amostras forma colhidas no distribuidor de uma máquina de lingotamento contínuo de placas, segundo critério que minimiza a possibilidade da ocorrência de interferências que pudessem mascarar o resultado do tratamento de refino secundário tais como re-oxidação do aço e coleta simultânea de escória. As amostras foram submetidas à análise de inclusões utilizando-se técnicas de microscopia óptica, microscopia eletrônica e micro-análise. Foi possível caracterizar as inclusões presentes em cada tipo de aço segundo a morfologia, o tamanho, a quantidade e a composição química. / Non-metallic inclusions in liquid samples of (I) low-carbon aluminium killed steel (0,02wpct C 0,08wpct), (II) peritetic aluminium and silicon killed steel (0,09wpct C 0,15wpct); (III) extra-low-carbon, aluminium killed steel (C<35 ppm) were taken from the tundish distributor of a continuous casting caster for steel plates according to a procedure that minimizes re-oxidation of steel and/or pick up of liquid slag. The samples were inspected through the following microstructural techniques: optical microscopy, electronic microscopy, and electron microprobe. Were possible to feature present inclusion in each kind of steel according to morphology, size, amout and chemical composition.

Please read the abstract (Summary) in the section, 00front of this document / Thesis (PhD (Electronic Engineering))--University of Pretoria, 2008. / Electrical, Electronic and Computer Engineering / PhD / unrestricted

The demand for higher quality steel and higher production rates in the production of steel slabs is ever increasing. These slabs are produced using a continuous casting process. The molten steel flow patterns inside the components of the caster play an important role in the quality of these products. A simple yet effective design method that yields optimum designs is required to design the systems influencing the flow patterns in the caster. The tundish is one of these systems. Traditionally, experimental methods were used in the design of these tundishes, making use of plant trials or water modelling. These methods are both costly and time consuming. More recently, Computational Fluid Dynamics (CFD) has established itself as a viable alternative to reduce the number of experimentation required, resulting in a reduction in the time scales and cost of the design process. Furthermore, CFD provides more insight into the flow process that is not available through experimentation only. The CFD process is usually based on a trial-and-error basis and relies heavily on the insight and experience of the designer to improve designs. Even an experienced designer will only be able to improve the design and does not necessarily guarantee optimum results. In this thesis, a more efficient design methodology is proposed. This methodology involves the combination of a mathematical optimiser with CFD to automate the design process. The methodology is tested on a four different industrial test cases. The first case involves the optimisation of a simple dam-weir configuration of a single strand caster. The position of the dam and weir relative to inlet region is optimised to reduce the dead volume and increase the inclusion removal. The second case involves the optimisation of a pouring box and baffle of a two-strand caster. In this case, the pouring box and baffle geometry is optimised to maximise the minimum residence time at operating level and a typical transition level. The third case deals with the geometry optimisation of an impact pad to reduce the surface turbulence that should result in a reduction in the particle entrainment from the slag layer. The last case continues from the third case where a dam position and height is optimised in conjunction with the optimised impact pad to maximise the inclusion removal on the slag layer. The cases studies show that a mathematical optimiser combined with CFD is a superior alternative compared to traditional design methods, in that it yields optimum designs for a tundish in a continuous casting system. / Thesis (PhD (Mechanical Engineering))--University of Pretoria, 2006. / Mechanical and Aeronautical Engineering / unrestricted

In modern times continuous casting is the preferred way to convert molten steel into solid forms to enable further processing. At Columbus Stainless the continuous casting machine cast slabs of constant thickness with varying width. One important aspect of the continuously cast strand that must be controlled, is the strand width. The strand width exiting from the casting machine, has a direct influence on the product yield which in turn influences the profitability of the company. In general, the strand width control on the austentic and ferritic type steels achieved is excellent with the exception of the 12% chrome non stabilised ferritic steel. This steel type exhibited different strand width changes when a sequence of different heats was cast. The strand width changes corresponded to the different heats in the sequence. Each heat has a unique chemistry and a relationship between the austenite and ferrite fraction at high temperature and the resulting strand width change was explained by Siyasiya[27]. The relationship between the heat composition and width change has in the past resulted in the development of a model that enabled the prediction of the expected width change of a specific heat before it is cast to enable preventative action to be taken. This model has been implemented as an on-line prediction model in the production environment with very encouraging results. This study was initiated because it was uncertain if the implemented model was the most accurate for this application. This study is concerned with the development of more models based on different techniques in an attempt to implement a more accurate model. The data mining techniques used include statistical regression, decision trees and fuzzy logic. The results indicated that the existing model was the most accurate and it could not be improved upon. / Dissertation (MEng (Mechanical Engineering))--University of Pretoria, 2007. / Mechanical and Aeronautical Engineering / MEng / unrestricted

The steel quality is deteriorated at a continuous casting start. Therefore, material from the first cast slab is cut off and re-melted in the melt shop. If too little is discarded, the inferior quality in the retained length can cause defects like edge cracks during subsequent hot rolling. This means that manufacturing resources are wasted on processing inferior material which has to be re-melted anyways at a later stage. On the other hand, if an excessive length of the first slab is re-melted, good material is wasted. In either case, optimizing the length of the start-scrap material is both economically and environmentally beneficial. Edge cracks are more common in the beginning of the first slab, even though a part is cut off. It is likely that the edge cracks arise due to reduced hot ductility in the first cast material. The purpose of this project is to optimize where the cut should be made in order to achieve the best yield. The hot ductility was investigated by performing hot tensile- and bending tests. The hot tensile tests indicate high hot ductility for the investigated specimens. The area reduction, which is correlated to the hot ductility, is above 70 % for all the investigated specimens. When considering the average area reduction while neglecting possible differences between the heats, the specimens from one meter tend to have a lower hot ductility compared to the other specimens. However, the differences are small. No difference can be seen between edge and middle specimens when only looking at the tensile tests. The bending tests did not crack without notches, even though the maximum load and a test temperature of 750 °C was used. That strongly indicates high hot ductility as well. By using notches, the bending tests cracked and it was shown that edge specimens and specimens from one meter cracked the most. No edge cracks were found, after hot rolling, on the first cast slabs from the investigated heats. / Vid en stränggjutstart är kvalitén på första slaben sämre. På grund av detta så skärs en bit, av det först gjutna slabet av och smälts om i stålverket. Om för lite material kapas av kan det leda till defekter, såsom kantbrakor, under den efterföljande varmvalsningen. Detta innebär att resurser används i onödan för att tillverka material av otillräcklig kvalitet som sedan ändå måste smältas om i ett senare steg. Skärs istället för mycket material bort så smälts prima material om i onödan. Att optimera startskrotlängden är följaktligen positivt både för miljön och rent ekonomiskt. Under varmvalsningen kan defekten kantbrakor, det vill säga sprickor vid kanterna, uppstå. Trots att en bit av det första gjutna slabet skärs av, så är det första slabet fortfarande mest utsatt för kantbrakor. Detta tros bero på nedsatt varmduktilitet i det första gjutna materialet. Syftet med detta projekt är att optimera längden på startskrotet för att spara så mycket användbart material som möjligt. Varmduktiliteten undersöktes genom drag- och bockprovning. Dragproven indikerar hög varmduktilitet för de undersökta proven. Areakontraktionen, som är ett mått på varmduktiliteten, är över 70 % för alla undersökta prov. Medelareakontraktionen, när man bortser från eventuella skillnader mellan chargerna, visar att prov från en meter generellt har något lägre varmduktilitet än de övriga proven. Det är endast små skillnader som uppfattas. Ingen skillnad kan ses mellan kant- och mittenprov när man enbart tittar på dragprovsresultaten. Bockproven sprack inte trots att maximal last användes och att testtemperaturen var 750 °C. Detta tyder också på hög varmduktilitet. Genom att skapa anvisningar kunde man få bockproven att spricka och det visade sig att kantprov och prov från en meter sprack mest. Inga kantbrakor hade uppstått på de första gjutna slabsen under varmvalsningen av försökschargerna.