Comsol Case Studies Continuous Casting: Optimizing Both Machine and Process with Simulation

	Continuous Casting: Optimizing Both Machine and Process with Simulation Comsol

Continuous Casting: Optimizing Both Machine and Process with Simulation

Comsol

Technology Category	Analytics & Modeling - Digital Twin / Simulation Analytics & Modeling - Predictive Analytics Application Infrastructure & Middleware - Data Visualization
Applicable Industries	Metals
Applicable Functions	Process Manufacturing Quality Assurance
Use Cases	Predictive Maintenance Process Control & Optimization Digital Twin
Services	Software Design & Engineering Services System Integration
Challenge	Continuous casting presents numerous variables that need to be analyzed to improve technology and advance the boundaries of steelmaking. The process involves transforming a constant stream of liquid steel into endless strands of solid metal, which requires precise control to minimize waste and improve yield. The challenge is to understand and simulate the complex processes involved in continuous casting, including fluid flow, solidification, and mechanical deformation, to achieve superior quality and cost efficiency. Read More
About Customer	SMS Concast is a leading company in the field of continuous casting, with over 60 years of experience in designing and building technical equipment for steel melting, refining, and continuous casting. The company holds a worldwide market share of over 40 percent and is known for pushing the limits of steelmaking technology. SMS Concast uses advanced simulation techniques to ensure their customers can produce high-quality steel products while reducing energy consumption and waste. The company has implemented innovative solutions in steel plants worldwide, including in Taiwan, Germany, and South Korea. Read More
Solution	SMS Concast uses simulation at every stage of the continuous casting process to analyze fluid flow, solidification, and mechanical deformation. They employ COMSOL Multiphysics to simulate the electromagnetic stirring of liquid steel, which is crucial for achieving high-quality steel with minimal non-metallic inclusions and even composition. The company also developed a new type of mold to cast billets with large rounded corners, allowing for hot charging directly to the rolling mill without reheating. This innovative mold design was successfully implemented at Tung Ho Steel in Taiwan, resulting in significant environmental and economic benefits. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Analytics & Modeling - Predictive Analytics

Application Infrastructure & Middleware - Data Visualization

Applicable Industries

Metals

Applicable Functions

Process Manufacturing

Quality Assurance

Use Cases

Predictive Maintenance

Process Control & Optimization

Digital Twin

Services

Software Design & Engineering Services

System Integration

Challenge

Continuous casting presents numerous variables that need to be analyzed to improve technology and advance the boundaries of steelmaking. The process involves transforming a constant stream of liquid steel into endless strands of solid metal, which requires precise control to minimize waste and improve yield. The challenge is to understand and simulate the complex processes involved in continuous casting, including fluid flow, solidification, and mechanical deformation, to achieve superior quality and cost efficiency.

About Customer

SMS Concast is a leading company in the field of continuous casting, with over 60 years of experience in designing and building technical equipment for steel melting, refining, and continuous casting. The company holds a worldwide market share of over 40 percent and is known for pushing the limits of steelmaking technology. SMS Concast uses advanced simulation techniques to ensure their customers can produce high-quality steel products while reducing energy consumption and waste. The company has implemented innovative solutions in steel plants worldwide, including in Taiwan, Germany, and South Korea.

Solution

SMS Concast uses simulation at every stage of the continuous casting process to analyze fluid flow, solidification, and mechanical deformation. They employ COMSOL Multiphysics to simulate the electromagnetic stirring of liquid steel, which is crucial for achieving high-quality steel with minimal non-metallic inclusions and even composition. The company also developed a new type of mold to cast billets with large rounded corners, allowing for hot charging directly to the rolling mill without reheating. This innovative mold design was successfully implemented at Tung Ho Steel in Taiwan, resulting in significant environmental and economic benefits.

Impact #1	Simulation is used to design electromagnetic stirrers correctly, ensuring the best steel quality.
Impact #2	The innovative mold design allows for hot charging, eliminating the need for reheating and reducing fossil fuel consumption.
Impact #3	The new mold design results in a more even surface temperature, improving the quality of the billets.

Impact #1

Simulation is used to design electromagnetic stirrers correctly, ensuring the best steel quality.

Impact #2

The innovative mold design allows for hot charging, eliminating the need for reheating and reducing fossil fuel consumption.

Impact #3

The new mold design results in a more even surface temperature, improving the quality of the billets.

Benefit #1	The innovative mold design at Tung Ho Steel reduces yearly CO2 emissions by 40,000 tons.
Benefit #2	The environmental benefit is equivalent to the exhaust of 20,000 cars.

Benefit #1

The innovative mold design at Tung Ho Steel reduces yearly CO2 emissions by 40,000 tons.

Benefit #2

The environmental benefit is equivalent to the exhaust of 20,000 cars.

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Overview

Continuous Casting: Optimizing Both Machine and Process with Simulation

Operational Impact

Quantitative Benefit