Continuous Casting: Optimizing Both Machine and Process with Simulation
Company Size
1,000+
Country
- Germany
- Taiwan
Product
- COMSOL Multiphysics
Tech Stack
- Simulation Software
- Electromagnetic Stirring
Implementation Scale
- Enterprise-wide Deployment
Impact Metrics
- Cost Savings
- Environmental Impact Reduction
- Innovation Output
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
- Digital Twin
- Predictive Maintenance
- Process Control & Optimization
Services
- Software Design & Engineering Services
- System Integration
About The 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.
The 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.
The 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.
Operational Impact
Quantitative Benefit
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