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Steel Refining Unit (SRU)

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Process Overview in LF
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SRU Process Control : Functions

Ladle from SMS waiting for
Treatment to start

Taken over for treatment

Bubbling Starts

De-Oxi Desulph Inclusion

Heating dation Alloying urisation cooling Dilution
modifn

Bubbling Ends

Treatment Ends
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SRU Process Control
Refining Model
Electrical
Production energy &
Chemistry
practice treatment
information
Alloying/
desulpurisation
deoxydation
calculation Material &
calculation
heat balance, Thermal
chemical
Model
reactions
recalculation
Metallurgical Model
Steel temp.
Bath Treatment,
Actual process values timings
Additions
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SRU Process Control
Refining model :Treatment Functions
Metallurgical Functions Method LF LRS
Temperature Adjstment Heating  NA
Cooling Scrap addition  
Homogenization Argon/Nitrogen Stirring  
De-oxidation Aluminum addition  
Alloying Material addition  
Steel Testing Temp/Oxygen Measurement  
Sampling  
Desulphurisation CaSi wire feeding  
Addition of slag forming agent  

Inclusion modification CaSi wire feeding  

Buffer between SMS and CCM Heating  NA
Recarburization Coke addition  
Insulation Addition of insulation powder  
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SRU Process Control
Typical refining pattern Stop
bubbling,
T/S/emf Temp T/S/emf Lift roof
Bubbling flow
Bubbling for
Lit/min/t Add
desulphurisation
2.5 Insuln
powder
1.0

0 1 3 5 10 12 16 18 28 30 33 34 35
Treatment
heating minutes

Slag forming agent

Alloying/recarburisation
Al wire
CaSi/CaFe wire
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SRU Process Control

 Refining plan
 Process Data Acquisition and Displaying
 Model Operation
– Treatment Control
– Refining guidance
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SRU Process Control
Available heat(s) for treatment
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SRU Process Control
Process Data Acquisition and Display
 Planned Data from Supervisory Computer
– Heat Order, Heat Data
 Steel Analysis from Laboratory
– Sample Place, Sample Type, Sample No., Analysis
 Actual Process Parameters and events
– Gas, Energy, Transformer tap, Water, Ladle weight
– Transfer car position
 Manual Operator inputs
– Manual Additions
– Suppliment missing data
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A typical Treatment status
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CONTINUOUS CASTING SHOP

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Caster Process Control
Major Functions
 Data Acquisition, displays / alarms
– Heat / plan / on-line data
– Process data (auto/manual)
 Material Tracking
 Dynamic casting speed calc./ CCM Pacing
 Dynamic control of strand cooling
 Slab Cut Length Optimization
 Mould width adjustment
 Computer Aided Quality Assurance
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Caster Process Control : Data Acquisition
Caster Production plan
 Heat and Plan Data
– HeatId,Grade, Weight,Temperature
– Bubbling duration
– Slab Dimensions
– Operator need to fill the data for unscheduled
heats
 Heat Overview Display
– Current/Waiting Heat status for the sequence
 HeatId, Seq. No., Steel Wt., Open time, Heat Status
Caster Process Control : Data Acquisition 19
Heat & plan data
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Caster Process Control : Data Acquisition
Sequence status
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Caster Process Control : Data Acquisition
Online Process Data and Displays
 Mold Cooling Data
– Water Flow Rate, Temp Difference, Inlet Temp
 Strand Data
– Withdrawal force, speed, temperatures in cooling
chamber, pressure casting bow, pressure straightener,
strand length
 Roll Table Devices
– Cutting m/c operation, cut length
– Weighing , marking ,deburrer and discharge area
 Ladle, Tundish and CAQA Push Button Data
– Ladle weight, ladle-cover, ladle arm pos , tundish data
– Shroud, nozzle, tundish problem, boiling in mold
 Chemical analysis
– Collected from R&C lab computer
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Online L1 Process Data and Displays
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Caster Process Control
Material Tracking in Caster
 Heat Tracking
– Tracking of material in terms of heat
 Strand Tracking
– Monitoring of flow of metal in ladle through tundish,
molds and strands continuously
– Updates the Casting Process Overview screen
continuously
 Product Tracking
– Tracks the product after cut
– Movement of slab thro’ deburrer, weighing m/c, Marking
m/c and discharge area devices
– Displays slab dimension, Weight,Quality flag
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Caster Process Control
Alarm and event logs
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Caster Process Control
Heat Pacing / Casting speed function
 Heat Pacing guidance
Expected current pouring end 5-Jan-02 15:40:24
– Expected ladle arrival time Expected next ladle arrival 5-Jan-02 15:40:39
Actual Steel temp in tundish 1549
– Expected Pouring End Time Recommended steel temp 1565
Steel Liquidus temperature 1529
– Displays Heat Pacing
Graphs with optimum Set Speed
m/minute Min Max
points 1.40 1.80
Required
 Casting Speed calculation 1.49

– Speed range given by Set point

1.49
CAQA module
Actual S1
– Tundish temperature 1.60
– Heat Pacing module Actual S2
recommendations 1.49

– Set points takes care of

02250078
Casting disturbance like 15:40:24
Nozzle change, tundish 14:17:02
change, casting stop etc. 15:40:39
02250079
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Caster Process Control
Cut Length Optimisation
 Advising proper moments of
strand closing
 Adjusting the cutting schedule
dynamically
 Model recalculates when:-
– Ladle pouring starts
– New heat enters mold
– Slab Cutting starts
– Mold width change etc.

Scrap
Scrap Bad Start
End Quality Remaining Last ordered
Segment Good Length Slab length

Point of influence Casting Direction

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Caster Process Control
Strand Cooling model
 Dynamic Cooling Model takes into account
– Caster Design parameters, process data & Events
– Steel grade practice table & pre-established cooling
pattern
– Calculates set points for the cooling loops and Start/Stop
set points

Strand On-line Set-point

parameters temperature calculation
Profile water flow
calculation set-points for
Actual process different
data &events Dynamic Cooling cooling zones
Cooling pattern
Caster Process Control 30

Strand Cooling model outputs

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Caster Process Control
Mould Width Control
Method Steps/mold side Width change
 Parallel mode 5mm 11-20 mm
 Z-wise mode 5mm > 20 mm
 Step mode 2mm < 20 mm

Next product

Actual
Taper
Safe distance length

Theoretical
Theoretical Safe Distance
Actual
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Caster Process Control
Computer Aided Quality Assurance
 CAQA System:
– Provides optimum operational parameters for every heat
– Tracks quality related process values
– Reports deviations
– Advises slab inspection, if required
Off-line On-line
metallurgical deviation report
data base casting CAQA
practice System
Insp. advice
Detection of (prime/insp/defect)
Process production
Actual tracking History data for
process deviation
data and metallurgical
events evaluation
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Caster Process Control
Optm. Parameters suggested by CAQA
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Typical CAQA ‘deviation report’

Misc Shop Supervisory Functions

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Misc Shop Supervisory Function

 Equipment Monitoring
– Recording and retrieval of Equipment Data
 Equipment Details, Status, Life, Usage time etc.
– Disturbance Data
 Type of disturbance, begin time, estimated end time,
 Monitoring of Supply, Stock, Consumption
– System provides facility to record
 Material Details Receipt , consumption (auto and manual inputs)
 Slab Yard management
– Managing the slab storage
– Slab movement within the slab yard
– Discharge of the slab from the slab yard
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Slab Inspection Requirement

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Computer Facilities in CCS

 Three tier Automation Scheme
– L1 : Basic automation with Instrumentation & electrics
– L2 : Process control functions
– L3 : Shop supervision /co-ordination
 CCS Computer Functional Expanse
– Production Management
 Scheduling, heat pacing, co-ordination & production overview
– Caster Process Control
 Steel tracking, Casting speed &CCm pacing, strand cooling
model, cut length optimisation, product overview
– Steel Refining Process Control
 Model guidance & control for Heating, alloying, additions,
bubbling etc to achieve aim steel grade
– Computer Aided Quality Assurance (CAQA)
– Miscellaneous Supervisory functions
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Computer system configuration

Shop Supervisory
Computer

SMS HSM
Computer Computer

Network Network
Bridge Bridge

Ethernet Chem.
Lab.
Computer

Development
CAQA & S/W Mtce
Computer Computer

Process Control
Computers for
SRU & Casters Terminals for
 Control Rooms
Gate Way  Shop Managers
 Slab Yard Manager

Basic Automation
Data Highway
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3000000

2500000 2594515

2000000

1500000

1000000
854105
500000

0
98-99 99-00 00-01 01-02 02-03 03-04 04-05
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HIGHLIGHTS OF SMS II - CCS

MAX. Nos. OF HEATS IN A SEQ. : 33 ON 31.3.2002

HIGHEST PRODUCTION IN A YEAR : 2594490TONS IN 04-05.
HIGHEST PRODN IN A MONTH : 231186 TON IN SEP’04
HIGHEST PRODUCTION IN A DAY : 9499 TON ON 30.09.03
HIGHEST HEAT CAST IN A DAY : 36 HEATS ON 30.11.04
HIGHEST HEAT CAST IN A SHIFT : 15 HEATS ON 30.11.04
HIGHEST DESPATCH IN A MONTH : 11415 No. / 227092.80 T
HIGHEST HEAT / SEQUENCE : 8.18 IN APRIL,01
HIGHEST LADLE LIFE : 61 HEATS
HIGHEST CONVERTOR LIFE : 2652 HEATS (RUNNING)
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We Remain Committed to the Growth
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and Prosperity of Our Nation..

Thank You