Design Exploration for Determining the Set Points of Continuous Casting Operation: An Industrial Application

2015 ◽  
Vol 137 (3) ◽  
Author(s):  
Rishabh Shukla ◽  
Sharad Goyal ◽  
Amarendra K. Singh ◽  
Jitesh H. Panchal ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Continuous Casting ◽  
Cost Effective ◽  
Computational Method ◽  
Production Costs ◽  
Unit Operation ◽  
Secondary Cooling ◽  
Product Mix ◽  
Conflicting Objectives ◽  
Light Weighting ◽  
Downstream Processes

To compete with other materials and/or contribute toward light-weighting of vehicles, newer grades of steel are continuously invented and experimented upon. Due to the costs and time involved in such developments, manufacture of new grades of steel at an industrial scale is difficult. We propose a method that is useful for steel manufacturers interested in producing a steel product mix with new grades of steels by predicting the required change in the operating set points of each unit operation in the manufacturing chain of products with the new grade of steel. Here, we demonstrate a method to determine the set points of one unit operation, continuous casting which is measured in terms of conflicting objectives including productivity, quality, and production costs. These parameters are sensitive to the operating set points of casting speed, superheat, mold oscillation frequency, and secondary cooling conditions. To ensure targeted performance and address the challenges of uncertainty and conflicting objectives, an integrated computational method based on surrogate models and the compromise decision support problem (cDSP) is presented. The method is used to explore the design space available for casting operations and determine operating set points to meet requirements imposed on the caster from subsequent downstream processes. This method is of value to the steel industry and enables the rapid and cost effective production of a product mix with a new grade of steel.

An Approach to Robust Process Design for Continuous Casting of Slab

2014 ◽  
Author(s):  
Rishabh Shukla ◽  
Sharad Goyal ◽  
Amarendra K. Singh ◽  
Jitesh H. Panchal ◽  
Janet K. Allen ◽  
...  
Keyword(s):  
Decision Support ◽  
Continuous Casting ◽  
Integrated Design ◽  
Performance Measure ◽  
Operating Conditions ◽  
Production Costs ◽  
Production Cycle ◽  
Performance Parameters ◽  
Steel Manufacturing ◽  
Conflicting Objectives

Continuous casting is a crucial step in the production of a variety of steel products. Its performance is measured in terms of conflicting objectives including productivity, yield, quality and production costs. These are conflicting in the sense that, if the productivity is increased, there is a reduction in other performance parameters. These performance parameters are greatly influenced by operating conditions such as casting speed, superheat, mold oscillation frequency, and secondary cooling conditions. An optimized solution for continuous casting process can be obtained. However uncertainty in operating parameters which affects the performance of caster is rarely considered. Moreover, the solution obtained is optimal with respect to a particular performance measure and does not provide a balance between all. In this paper an integrated design framework has been developed based on metamodels and the compromise Decision Support Problem (cDSP). The framework developed deals with uncertainty and yields robust solutions for performance measures. Further, the design space for continuous casting has been explored for different scenarios to determine satisficing solutions. The utility of the framework has been illustrated for providing decision support when an existing configuration for continuous casting is unable to meet the requirements. This approach can be instantiated for other unit operations involved in steel manufacturing and then may be integrated to simulate the entire production cycle of steel manufacturing. This in turn will enable development of materials with specific properties and reduce the time and cost incurred in the development of new materials and their manufacturing.

Solution Space Exploration of the Process Design for Continuous Casting of Steel

2016 ◽  
Author(s):  
Maryam Sabeghi ◽  
Rishabh Shukla ◽  
Janet K. Allen ◽  
Farrokh Mistree
Keyword(s):  
Continuous Casting ◽  
Performance Measures ◽  
Solution Space ◽  
Quality Parameters ◽  
Operating Conditions ◽  
Production Costs ◽  
Steel Mill ◽  
Casting Operation ◽  
Conflicting Objectives ◽  
Plant Trials

Continuous casting is the process of solidifying molten metal to produce different products such as billet, bloom, or slab. This process can be formulated mathematically in terms of conflicting objectives including productivity, yield, quality and production costs to satisfy sets of constraints such as oscillation mark depth, metallurgical length and center line segregation. The objectives are conflicting in the sense that, if the productivity is increased, there is a reduction in other performance measures. These performance specifications are greatly influenced by operating conditions such as casting speed, superheat, mold oscillation frequency, and secondary cooling conditions. The process of identifying the set points for the continuous casting operation is iterative and expensive. The uncertainties inherent in modeling the phenomena computationally behooves exploration of the solution space to determine the quality of the solution and gain insight. In this paper, a method to explore the solution space is introduced. The method includes weight sensitivity and constraint sensitivity analysis. This analysis allows a designer to ascertain to what extent the solution is insensitive to uncertainties inherent in the modeling of the decision problem. This is a crucial step towards determining robust solutions for performance measures. The utility of the method is illustrated in providing decision support for the continuous casting operation in presence of variability in the operating parameters and conflicting end requirements, such as productivity and quality parameters. This method can be instantiated for exploring the solution space for ladle, tundish, rolling and annealing and thereby facilitating the exploration of the solution space for critical unit operations associated with steel product manufacturing. This development has the potential to reduce the number of plant trials necessary to determine the set points for manufacturing a new product mix with a new grade of steel using the existing equipment in a steel mill. The focus in this paper is on the method and not the results per se.

Computational Methods to Support Brittle Fracture Assessment of PSVs Involving Autorefrigeration

2015 ◽  
Author(s):  
Kannan Subramanian ◽  
Jorge Penso ◽  
Harbi Pordal
Keyword(s):  
Brittle Fracture ◽  
Computational Methods ◽  
Cost Effective ◽  
Liquid Hydrocarbon ◽  
Computational Method ◽  
Metal Temperature ◽  
Relief Valve ◽  
Sensitivity Studies ◽  
Fracture Assessment ◽  
Cfd Method

Pressure safety relief valve (PSV) operation generally leads to cooling of the valve itself and the piping connected to the PSV. The temperatures may reach values below the minimum design metal temperature (MDMT) of the valve, and therefore the valve needs to be assessed for brittle fracture susceptibility. Simplistic determination of the minimum metal temperature in the valve may disqualify these valves during the brittle fracture assessments (BFA). Replacement may be time consuming and may not be cost effective. In such circumstances, a sophisticated and more representative BFA approach involving the use of computational fluid dynamics (CFD) followed by finite element method (FEM) based stress analysis which may be further followed by fracture mechanics can be adopted based on the concepts defined in ASME/API 579. The accuracy of the BFA depends on the accuracy of each of the computational method involved in the assessment. Among all the computational methods, CFD poses significant challenge. The low temperature may have been caused due to Joule-Thompson effect or auto-refrigeration. While Joule-Thompson effect can be best captured with easy to implement and robust CFD methods, auto-refrigeration involving adiabatic flashing which causes additional complexity and requires multiple sensitivity studies performed to determine the accuracy of the CFD approach. In this paper, an overview of the computational methods used in the brittle fracture assessment of PSVs is presented. Specific CFD method details are provided for PSV involving the flashing of liquid hydrocarbon to vapor is presented in the form of a case study derived from downstream industry application.

scholarly journals Convective Drying at Fish Chips Technology

2020 ◽  
Author(s):  
Vyacheslav Pokholchenko ◽  
Aleksandra Smirnova ◽  
Yana Glukhikh
Keyword(s):  
Raw Materials ◽  
Cost Effective ◽  
Heat Pumps ◽  
Production Costs ◽  
Convective Drying ◽  
Fish Processing ◽  
Resource Saving ◽  
Technological Processes ◽  
Modes Of Processing ◽  
Minced Fish

The article presents the overview of the main technological processes in fish structured products dehydration. The rational modes of the technological process of minced fish raw materials with various initial moisture and fat content heat treatment are determined. One of the main tasks of the fish processing industry development which allows increasing the profitability of products and their quality is improving technological processes. The scientifically substantiated choice of resource and energy-saving modes of processing food materials is highly important in this case. It will reduce not only production costs but also emissions of harmful substances into the environment and increase the efficiency of using equipment. It must be taken into consideration that the optimization of dehydration technological processes without identifying their patterns is extremely difficult. Increasing efficiency and controlling technological processes makes sense only on the basis of patterns. The effectiveness of the hydrobionts processing determines the quality and cost of finished products manufacturing while fish processing enterprises working. The development and implementation of highly efficient technologies with the use of resource-saving technical systems, for example, using heat pumps, makes it possible to produce cost-effective high-quality products.

Leveraging Glass Properties for Advanced Packaging

2015 ◽  
Vol 2015 (1) ◽  
pp. 000370-000374
Author(s):  
A.B. Shorey ◽  
Y.J. Lu ◽  
G.A. Smith
Keyword(s):  
Coefficient Of Thermal Expansion ◽  
Cost Effective ◽  
High Frequencies ◽  
Glass Substrates ◽  
Glass Forming ◽  
Cost Structures ◽  
Advanced Packaging ◽  
Downstream Processes ◽  
Electrical Loss ◽  
Made In

Glass provides many opportunities for advanced packaging. The most obvious advantage is given by the material properties. As an insulator, glass has low electrical loss, particularly at high frequencies. The relatively high stiffness and ability to adjust the coefficient of thermal expansion gives advantages to manage warp in glass core substrates and bonded stacks for both through glass vias (TGV) and carrier applications. Glass also gives advantages for developing cost effective solutions. Glass forming processes allow the potential to form both in panel format as well as at thicknesses as low as 100 um, giving opportunities to optimize or eliminate current manufacturing methods. As the industry adopts glass solutions, significant advancements have been made in downstream processes such as glass handling and via/surface metallization. Of particular interest is the ability to leverage tool sets and processes for panel fabrication to enable cost structures desired by the industry. By utilizing the stiffness and adjustable CTE of glass substrates, as well as continuously reducing via size that can be made in a panel format, opportunities to manufacture glass TGV substrates in a panel format increase. We will provide an update on advancements in these areas as well as handling techniques to achieve desired process flows. We will also provide the latest demonstrations of electrical, thermal and mechanical reliability.

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