Cloud-based simulation of continuous casting

Cloud-based simulation of continuous casting
Summary

The result of this experiment is the abilityto simulate the flow of steel in a metal casting process using Cloud-based HPC resources so that Ergolines can use the results of the simulation to develop an effective slag detection system. Dedicated numerical simulations based on Cloud-based HPC resources has enabled Ergolines’ researchers to perform a thorough analysis of the different ladle emptying mechanisms. As a result, it has been possible to establish a correlation between the shroud vibrational signal and the fluid dynamic of the system. Based on this, it is now possible to develop a novel technology for the detection of ladle slag based on vibrational analysis. By preventing slag from passing from ladle to tundish, this innovative system would reduce the risk of breakouts, thus addressing key safety issues and contributing to an increase steel plants’ productivity. In order to prevent slag transfer into the tundish, the pouring of liquid steel must be interrupted before the ladle is completely empty. The ability to detect the slag while it is passing through the shroud would enable the steel plant to delay the closing of the ladle, with an estimated saving of 1% of its production costs. In order to produce 1 million tons of steel per year, a medium size factory must sustain steel costs of up to 300 M€. Envisioned annual savings for a medium size factory are around 3 M€ for low-medium quality steel, rising significantly for higher-quality cast products. Fast return on investment is thus guaranteed, together with full coverage of the overall simulation costs. In fact, if no access to HPC resources and services had been granted, the overall simulation costs, comprehensive of hardware and personnel, would have been ~ €130,000.

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