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.

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.

scholarly journals HeProMo: A decision support tool to estimate wood harvesting productivities

PLoS ONE ◽  
2020 ◽  
Vol 15 (12) ◽  
pp. e0244289
Author(s):  
Stefan Holm ◽  
Fritz Frutig ◽  
Renato Lemm ◽  
Oliver Thees ◽  
Janine Schweier
Keyword(s):  
Decision Support ◽  
Forest Management ◽  
Decision Support Tool ◽  
Operating Conditions ◽  
Production Costs ◽  
Forest Operations ◽  
Support Tool ◽  
Central European ◽  
Wood Harvesting ◽  
Input Variables

In the field of forestry, one of the most economically important ecosystem service is the provision of timber. The need to calculate the economic effects of forest management in the short, medium, and long term is increasing. Forest operations or timber harvesting, which comprises felling, processing, and transport of trees or timber, are responsible for a large part of the costs and environmental impacts associated to forest management or enterprises. From a decision maker’s perspective, it is essential to estimate working productivity and production costs under given operating conditions before any operation is conducted. This work addresses the lack of a valid collection of models that allows estimating time, productivities, and costs of labor and machinery for the most important forest operations in forest stands under Central European conditions. To create such models, we used data from forest enterprises, manual time studies, and the literature. This work presents a decision support tool that estimates the wood harvesting productivities of 12 different kinds of forest operations under Central European conditions. It includes forest operations using chainsaws, harvesters, skidders, forwarders, chippers, cable and tower yarders, and helicopters. In addition, the tool covers three models for wood volume estimation. The tool is written in Java and available open-source under the Apache License. This work shows how the tool can be used by describing its graphical user interface (GUI) and its application programming interface (API) that facilitates bulk processing of scientific data. Carefully selected default values allow estimations without knowing all input variables in detail. Each model is accompanied by an in-depth documentation where the forest operation, input variables, formulas, and statistical background are given. We conclude that HeProMo is a very useful tool for applications in forest practice, research, and teaching.

Power Test System Development and Dynamic Performance State Estimation Based on Hub Motor Vehicle

2020 ◽  
Vol 13 (2) ◽  
pp. 126-140
Author(s):  
Jing Gan ◽  
Xiaobin Fan ◽  
Zeng Song ◽  
Mingyue Zhang ◽  
Bin Zhao
Keyword(s):  
Real Time ◽  
Dynamic Performance ◽  
Test System ◽  
Operating Conditions ◽  
Motor Vehicles ◽  
Maximum Speed ◽  
Performance Parameters ◽  
Power Performance ◽  
Power Test ◽  
The Real

Background: The power performance of an electric vehicle is the basic parameter. Traditional test equipment, such as the expensive chassis dynamometer, not only increases the cost of testing but also makes it impossible to measure all the performance parameters of an electric vehicle. Objective: A set of convenient, efficient and sensitive power measurement system for electric vehicles is developed to obtain the real-time power changes of hub-motor vehicles under various operating conditions, and the dynamic performance parameters of hub-motor vehicles are obtained through the system. Methods: Firstly, a set of on-board power test system is developed by using virtual instrument (Lab- VIEW). This test system can obtain the power changes of hub-motor vehicles under various operating conditions in real-time and save data in real-time. Then, the driving resistance of hub-motor vehicles is analyzed, and the power performance of hub-motor vehicles is studied in depth. The power testing system is proposed to test the input power of both ends of the driving motor, and the chassis dynamometer is combined to test so that the output efficiency of the driving motor can be easily obtained without disassembly. Finally, this method is used to carry out the road test and obtain the vehicle dynamic performance parameters. Results: The real-time current, voltage and power, maximum power, acceleration time and maximum speed of the vehicle can be obtained accurately by using the power test system in the real road experiment. Conclusion: The maximum power required by the two motors reaches about 9KW, and it takes about 20 seconds to reach the maximum speed. The total power required to maintain the maximum speed is about 7.8kw, and the maximum speed is 62km/h. In this article, various patents have been discussed.

scholarly journals Cycle-oriented approach to building a model of production costs

2020 ◽  
Vol 17 ◽  
pp. 00124
Author(s):  
Elena P. Polikarpova ◽  
Igor E. Mizikovskiy
Keyword(s):  
Cost Management ◽  
Modern Science ◽  
Management Control ◽  
Point Of View ◽  
Production Costs ◽  
Production Cycle ◽  
Agricultural Activity ◽  
Management Tools ◽  
Agricultural Enterprises ◽  
Oriented Approach

Modern science and practice does not have a sufficient set of cost management tools, taking into account the duration of the production cycle, characteristic of agricultural activity. The implementation of a cycle-oriented approach to building a model of production costs was based on studying the existing options for classifying production costs, which were supplemented with features from the perspective of managing long production cycles. As a result of the study, a model of production costs was built from the point of view of a cycle-oriented approach, as well as a model of production costs from the standpoint of features of a long production cycle. The model can serve as the basis for the formation of the information space of cost management, control and cost analysis in the economy of agricultural enterprises.

Agglomeration Technologies of Processing Powder Wastes

2015 ◽  
Vol 244 ◽  
pp. 121-129
Author(s):  
Marian Peciar ◽  
Roman Fekete ◽  
Peter Peciar
Keyword(s):  
Research Work ◽  
Operating Conditions ◽  
Airborne Particles ◽  
Raw Material ◽  
Production Cycle ◽  
Shear Forces ◽  
Material Resources ◽  
New Type ◽  
Two Phases ◽  
High Technologies

This article deals with the presentation of modern applications for processing powdered, primarily hazardous, waste to an agglomeration form appropriate for subsequent processing by classical methods, for example in the construction, automotive and consumer goods industries. The aim of the research work was to set appropriate operating conditions in order to appreciate currently non-processable wastes resulting from the intensive production of often extremely expensive materials. Technologies which enable returning powder waste back into the primary production cycle were developed and experimentally tested, thus saving raw material resources. When necessary for the fixing of fine airborne particles with a problematic compacting curve (hard to compress, repulsive due to the surface charge) extrusion processes using a patented technology enabling controlled modification of shear forces in the extrusion zone were successfully applied. A new type of axial extruder allows the elimination of the liquid phase and as a result prevents the clogging of the extrusion chamber. In the case of need for granulation of sensitive materials (for example pharmaceuticals not allowing the addition of any kind of agglomerating fluid or reacting strongly in the contact of the two phases), a process of compaction between rolls with different profiled surface was successfully applied. The developed high technologies and the resulting products thus represent a major contribution to environmental protection in the context of not only the work but also the communal environment.

Asphaltene Mitigation in Giant Carbonate Abu Dhabi Fields: A Techno-Economic Comparison Between Continuous Injection and Formation Squeeze

2021 ◽  
Author(s):  
Mark Grutters ◽  
Sameer Punnapala ◽  
Dalia Salem Abdallah ◽  
Zaharia Cristea ◽  
Hossam El Din Mohamed El Nagger ◽  
...  
Keyword(s):  
Cost Effective ◽  
Threshold Value ◽  
Field Trials ◽  
Mitigation Strategy ◽  
Operating Conditions ◽  
Mitigation Strategies ◽  
Production Cycle ◽  
Asphaltene Precipitation ◽  
Coiled Tubing ◽  
Continuous Injection

Abstract Asphaltene deposition is a serious and re-occurring flow assurance problem in several of the ADNOC onshore oilfields. Fluids are intrinsically unstable with respect to asphaltene precipitation, and operating conditions are such that severe deposition occurs in the wellbore. Wells in ADNOC are generally not equipped with downhole chemical injection lines for continuous inhibition, and protection of the wells require frequent shut-in and intervention by wireline and coiled tubing to inspect and clean up. Since some of the mature fields are under EOR recovery strategies, like miscible hydrocarbon WAG and CO2 flood, which exacerbates the asphaltene precipitation and deposition problems, a more robust mitigation strategy is required. In this paper the results of two different mitigation strategies will be discussed; continuous injection of asphaltene inhibitor via a capillary line in the tubular and asphaltene inhibitor formation squeeze. Three asphaltene inhibitors from different suppliers were pre-qualified and selected for field trial. Each inhibitor was selected for a formation squeeze in both one horizontal and one vertical well, and one of the inhibitors was applied via thru-tubing capillary string. The field trials showed that continuous injection in remote wells with no real-time surveillance options (e.g. gauges, flow meters) is technically challenging. The continuous injection trial via the capillary string was stopped due to technical challenges. From the six formation squeezes four were confirmed to be effective. Three out of fours squeezes significantly extended the production cycle, from approximately 1.4 to 6 times the normal uninhibited flow period. The most successful squeezes were in the vertical wells. The results of the trial were used to model the economic benefit of formation squeeze, compared to a ‘do-nothing’ approach where the wells are subject to shut-in and cleanup once the production rates drop below a threshold value. The model clearly indicates that the squeezes applied in ADNOC Onshore are only cost-effective if it extends the normal flow period by approximately three times. However, a net gain can be achieved already if the formation squeeze extends the flow cycle by 15 to 20%, due to reduction of shut-in days required for intervention. Therefore, the results in this paper illustrate that an asphaltene inhibitor formation squeeze can be an attractive mitigation strategy, both technically and economically.

scholarly journals Improvement of operation of steam cushion system for sensible thermal energy storage

2019 ◽  
Vol 116 ◽  
pp. 00107
Author(s):  
Ryszard Zwierzchowski
Keyword(s):  
Heat Flux ◽  
Energy Storage ◽  
Thermal Energy ◽  
Thermal Energy Storage ◽  
Energy Savings ◽  
Operating Conditions ◽  
Production Costs ◽  
Technical Solution ◽  
Atmospheric Air ◽  
Suction Pipe

The paper contains a method for improvement of operation of steam cushion system including its energy savings analyses, for a Thermal Energy Storage (TES) tank. Energy savings analyses were performed using operational data from selected Combined Heat and Power plants, which supply heat to large cities in Poland and are furnished with the TES. The role of the steam cushion system in the TES tank is to prevent the stored water against absorbing oxygen from atmospheric air. In the TES tank, which is a non-pressure tank, oxygen from atmospheric air could penetrate to the network water through the surge chamber and safety valves. The steam pressure under the roof is generated from technological steam injected under the roof. Energy savings in the steam cushion system are generated by using an appropriate technical solution for the upper orifice and suction pipe for circulation water, i.e., to make it movable through the use of pontoons. An isolating buffer layer is created at the top of the tank with very small convective and turbulent heat transport, which causes limited heat transfer from steam bed to the stored water in the tank. This results in heat flux of approximately 10% of the heat flux that occurs in the typical technical solution of the upper orifice and suction pipe for circulation water in the TES tank. This technology offers great opportunities to improve the operating conditions of District Heating System, cutting energy production costs and emissions of pollutants to the atmosphere.

scholarly journals MACHoice: a Decision Support System for agricultural machinery management

2019 ◽  
Vol 4 (1) ◽  
pp. 305-321 ◽  
Author(s):  
M. Cunha ◽  
S.G. Gonçalves
Keyword(s):  
Decision Support ◽  
Decision Support System ◽  
Support System ◽  
Crop Production ◽  
Work Capacity ◽  
Production Costs ◽  
Modern Agriculture ◽  
Level Of Automation ◽  
High Level ◽  
User Friendly

AbstractMechanisation is a key input in modern agriculture, while it accounts for a large part of crop production costs, it can bring considerable farm benefits if well managed. Models for simulated machinery costs, may not replace actual cost measurements but the information obtained through them can replace a farm’s existing records, becoming more valuable to decision makers. MACHoice, a decision support system (DSS) presented in this paper, is a farm machinery cost estimator and break-even analyzer of alternatives for agricultural operations, developed using user-driven expectations and in close collaboration with agronomists and computer engineers. It integrates an innovative algorithm developed for projections of machinery costs under different rates of annual machine use and work capacity processing, which is crucial to decisions on break-even machinery alternatives. A case study based on the comparison of multiple alternatives for grape harvesting operations is presented to demonstrate the typical results that can be expected from MACHoice, and to identify its capabilities and limitations. This DSS offers an integrated and flexible analysis environment with a user-friendly graphical interface as well as a high level of automation of processing chains. The DSS-output consists of charts and tables, evidencing the differences related to costs and carbon emissions between the options inserted by the user for the different intensity of yearly work proceeded. MACHoice is an interactive web-based tool that can be accessed freely for non-commercial use by every known browser.

Sign in / Sign up

Export Citation Format

Share Document