Q- C ORE and Dynamic soft reduction technology for ...D A N IELI TEC HN OLO G ICAL PAC K A G ES F...
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117 116 Q-CORE and Q-PULSE Dynamic soft reduction technology for continuous slab casters BENEFITS Possibility of installing it on existing slab casters Improved internal quality in terms of: > Internal cracks > Centerline segregation > Centerline porosity The ability to measure the position of the liquid pool (Q-PULSE) Fewer rejects on hot-rolled coil / plate ROI < 1 year EQUIPMENT Q-CORE utilizes signals coming from the linear transducers installed in the on-board clamping cylinders of the caster segments, combined with instantaneous casting data coming from the main control PLC, to adjust the roll-gap settings of each segment along the caster strand automatically. The system uses the steel grade, casting speed, steel temperature, etc., and compares the actual solidification profile with the optimal desired one, and then will adjust the segment roll-gap settings to ensure the actual solidification profile matches the optimum. PROCESS The slab centerline quality of particular steel grades (i.e., plate and line pipe grades) is critical and the Q-CORE system was developed to provide the dynamic soft reduction settings and position control to achieve required slab internal quality. During non-steady-state casting conditions, (e.g., a change in speed or change in liquid steel superheat), a change in the solidification rate of the strand occurs and hence the final point of solidification moves. With the Q-CORE system these changes can be accommodated and the roll gap automatically adjusted during casting to ensure no loss of slab quality. Q-CORE works by continuously monitoring the solidification behavior of the slab and dynamically adjusting the segment roll gap settings. In order to validate the correctness of the mathematical estimation of the solidification length, Danieli provides the Q-PULSE system, 6 5 4 A 3 2 1 0 Min Max Quality index Casting speed (mpm) 6 5 4 3 B 2 1 0 Min Max Casting speed (mpm) Quality index PROCESS CONTROL Q-CORE Process Control uses a solidification mathematical model that calculates the liquid pool length. To verify the result of the mathematical calculation of the solidification length, Danieli provides the Q-PULSE system. Here, an example of a casting start monitored by Q-CORE. The temperature profile changes both in the strand and graphic window. The page also shows core/sides/corner temperature profiles, cooling flow overview, and liquid pool data. PERFORMANCE ACHIEVEMENTS Q-CORE should allow plant operators to move into higher value-added markets that demand superior internal quality. If we assume an additional 50 USD/t margin due to improved quality, and the customer can access 300,000 tpy of this market, i.e., 30% quality / 70% commercial, then the marginal increase totals 15 M USD per year. Q-CORE system has been proven to consistently give the highest internal quality levels, particularly for plate and line pipe applications. Q-CORE has been installed on slab casters ranging in thickness from 55 mm to 350 mm. Conventional static soft reduction. A - quality maintained for narrow casting speed range. Danieli Automation HMI display designed to give clear and immediate information. Dynamic soft reduction with Q-CORE. B - quality maintained over full casting speed range. Segment loose side oscillation Segment oscillation detected by mold level control system Segment loose side oscillation No change in mold level from segment oscillation DANIELI TECHNOLOGICAL PACKAGES FLAT PRODUCTS / CONTINUOUS CASTING Flat Products Actual macroetch prints showing uniform centre line solidification across the whole slab width with the correct application of Q-CORE. (API X70; slab width: 2,500 mm) which is capable of detecting the presence of the liquid pool by oscillating the loose side of the segment with a controlled frequency, and cross-checking the displacement and the amplitude of this oscillation using FFT analysis in the mold-level control system.
Transcript of Q- C ORE and Dynamic soft reduction technology for ...D A N IELI TEC HN OLO G ICAL PAC K A G ES F...
117116
Q-CORE andQ-PULSE
Dynamic soft reduction technology for continuous slab casters
BENEFITS
Possibility of installing it on existing slab castersImproved internal quality in terms of:> Internal cracks> Centerline segregation> Centerline porosityThe ability to measure the position of the liquid pool (Q-PULSE)Fewer rejects on hot-rolled coil / plateROI < 1 year
EQUIPMENT
Q-CORE utilizes signals coming from the linear transducers installed in the on-board clamping cylinders of the caster segments, combined with instantaneous casting data coming from the main control PLC, to adjust the roll-gap settings of each segment along the caster strand automatically. The system uses the steel grade, casting speed, steel temperature, etc., and compares the actual solidification profile with the optimal desired one, and then will adjust the segment roll-gap settings to ensure the actual solidification profile matches the optimum.
PROCESS
The slab centerline quality of particular steel grades (i.e., plate and line pipe grades) is critical and the Q-CORE system was developed to provide the dynamic soft reduction settings and position control to achieve required slab internal quality.During non-steady-state casting conditions, (e.g., a change in speed or change in liquid steel superheat), a change in the solidification rate of the strand occurs and hence the final point of solidification moves. With the Q-CORE system these changes can be accommodated and the roll gap automatically adjusted during casting to ensure no loss of slab quality.Q-CORE works by continuously monitoring the solidification behavior of the slab and dynamically adjusting the segment roll gap settings.In order to validate the correctness of the mathematical estimation of the solidification length, Danieli provides the Q-PULSE system,
6
54
A
3
2
1
0Min Max
Qua
lity
inde
x
Casting speed (mpm)
6
54
3B
2
1
0Min Max
Casting speed (mpm)
Qua
lity
inde
x
PROCESS CONTROL
Q-CORE Process Control uses a solidification mathematical model that calculates the liquid pool length.To verify the result of the mathematical calculation of the solidification length, Danieli provides the Q-PULSE system.Here, an example of a casting start monitored by Q-CORE. The temperature profile changes both in the strand and graphic window. The page also shows core/sides/corner temperature profiles, cooling flow overview, and liquid pool data.
PERFORMANCE ACHIEVEMENTS
Q-CORE should allow plant operators to move into higher value-added markets that demand superior internal quality. If we assume an additional 50 USD/t margin due to improved quality, and the customer can access 300,000 tpy of this market, i.e., 30% quality / 70% commercial, then the marginal increase totals 15 M USD per year.Q-CORE system has been proven to consistently give the highest internal quality levels, particularly for plate and line pipe applications.Q-CORE has been installed on slab casters ranging in thickness from 55 mm to 350 mm.
Conventional static soft reduction.
A - quality maintained for narrow casting speed range.
Danieli Automation HMI display designed to give clear and immediate information.
Dynamic soft reduction with Q-CORE.
B - quality maintained over full casting speed range.
Segment loose side oscillation
Segment oscillationdetected by moldlevel control system
Segment loose side oscillation
No change in moldlevel from segment oscillation
DANIELI TECHNOLOGICAL PACKAGES FLAT PRODUCTS / CONTINUOUS CASTING
Flat Products
Actual macroetch prints showing uniform centre line solidification across the whole slab width with the correct application of Q-CORE. (API X70; slab width: 2,500 mm)
which is capable of detecting the presence of the liquid pool by oscillating the loose side of the segment with a controlled frequency, and cross-checking the displacement and the amplitude of this oscillation using FFT analysis in the mold-level control system.
