The recently launched ABB Ability Optimold Control system corrects metal casting problems in the mold and ensures that casting takes place under optimal conditions.
It works in real-time, using feedback from a high-resolution sensor system (such as ABB Ability Optimold Monitor) to actively control electromagnetic devices such as stirrers or brakes which can influence fluid flow.
Combining with ABB’s existing product suite for steel manufacturers, the controller is claimed to give instant and optimal process control in the mold, resulting in higher product quality, improved productivity and enhanced efficiency in the slab casting process while helping avoid quality downgrades.
ABB has also developed a product version specifically for use with a new type of electromagnetic brake (EMBR) in the conventional or thin slab continuous steel casting process.
ABB Ability Optimold Control for EMBR independently controls the new EMBR’s flexible left and right sides and takes advantage of its flexible front core configuration, which enables it to work with any submerged entry nozzle (SEN) shape.
The resulting real-time, online control optimises melt flow speed, symmetry and stability control.
“Previously, we have offered electromagnetic device control systems that rely solely on macroscopic casting parameters such as casting speed and slab format,” says Anders Lehman, Vice President of ABB Metallurgy Products.
“Our new ABB Ability Optimold Control elevates such systems to a closed-loop, using sensors that quickly identify and correct variations in the casting process that may be otherwise be missed, such as meniscus fluctuations, biased flow due to clogging, irregular flow patterns or improper meniscus flow speeds.”
“With this real-time, online control system, the continuous casting process becomes more robust, dangerous events can be avoided and both product quality and energy efficiency are improved.”