A new dynamic control model based on simultaneous mass transfer of C, Cr, and Mn and dynamic heat balance is developed. It allows dynamic adjustment of argon-oxygen ratio. The model is implemented through Level II control system. The total operating period of one heat is divided into five different stages: charge calculation, first blow period, second blow period, third blow period and, lastly, the reduction stage. The charge calculation model, based on heat balance, mass balance and the costs decided the optimum charge mix to start with. Both linear and non-linear regression models are used to predict the temperature and composition of bath at the end of first blow period. The second blow and the third blow periods use the dynamic models for predicting the chemical composition and temperature. In the model for reduction stage (final stage) the amount of reduction mixture is determined for obtaining maximum recovery of Cr and Mn from slag. On-line testing of the dynamic models was carried out on the shop floor. The integration of models with the Level II control system using Supervisory Control and Data Acquisition System (SCADA) are discussed. User friendly HMI are developed such that the operators can easily use it during the regular operation on shop-floor. This is the first time that a full dynamic control system was implemented in India for the AOD process.
Applying of Real-time Heat Transfer and Solidification Model on the Dynamic Control System of Billet Continuous Casting
