This harmonization of the automation solutions will simplify the control and optimization of the production processes. One advantage of the new solution is that the calculation algorithms and software models have additional potential to improve strand cooling, speed- & width control and thus improve production performance and right first time casting.
Step-by-step remote commissioning with online support in real time
The correct coupling to the Level 1 system and the existing IT environment at Tata Steel Europe had previously been tested in several cold-runs with on-site support of Primetals. All 10 hot-runs and commission were supported on-line, resulting in the successful casting of 140 Heats with a total of 1900 slabs in mid-June 2019.
Harmonization of the automation solutions
The Level 2 system from Primetals Technologies replaced an existing automation solution that had been in operation for over 20 years. In addition to replacing the outdated system the main reason behind the modernization was the harmonization of all the caster automation systems (CC21, CC22 and the new CC23) used by Tata Steel Europe in its IJmuiden plant. The new Continuous caster CC23 is currently under construction and will also be equipped with the Level 2 system from Primetals. Valuable experience has been gained from the commissioning on the CC21 plant and applied to the preparations for the CC23 plant. In particular, the coupling of the solution to the existing IT infrastructure of Tata Steel Europe can now be used again, which will substantially reduce the effort required to commission the new plant.
Sophisticated calculation algorithms and software models
Tata Steel Europe benefits from the new Level 2 solution from Primetals, especially from the sophisticated calculation algorithms and software models included as standard. Models and simulations are already being used to gradually further improve secondary cooling maintaining a defined surface temperature profile throughout the entire casting sequence. The system also continuously adjusts the width of the strand on the basis of the data calculated in real time, which makes a major contribution towards first time right order fulfillment. Another function calculates the optimal casting speed of the continuous caster on the basis of various parameters – such as temperature distribution, throughput, analysis and scheduling – enabling a stable casting operation to be maintained.
_{(Source: Primetals Technologies Limited)}