A model of automated mold flux feeding into the crystallizer of a continuous casting machine

This paper describes a model of automatic mold flux (MF) feeding into the crystallizer of a continuous casting machine (CCM). The MF is used to protect metal from secondary oxidation, to lubricate the billet crustand the  mold wall, and to fulfill some other functions. Most Russian steel plants use imported MF due to their higher quality and the use of imported CCMs. The effective consumption of MF is essential due to its high cost. Obtaining preliminary data from the model with the introduction of new equipment and expanding the range of steel in steel making shops is an urgent task. Therefore, a model of automated MF feeding has been developed, which can be modified by changing casting parameters. A detailed description of the model developed in Matlab Simulink software is provided. The distinctive features of the model include the relationships between the metal and slag temperature difference, slag layer thickness, and screw feeder flow rate. Mathematical expressions for these relationships are derived and a description of the structural automation diagram and the functional diagram of the model is presented. Model-based equipment settings (electric drive parameters and sensor parameters) and the introduction of the proposed control algorithm reduces flux consumption by up to 13 % while reducing the manufacturing costs of the final product by up to 6 %.