In recent years, data-driven technologies have revolutionized steelmaking — and the most successful steelmakers are relying on data analytics to optimize their continuous casting process. We previously covered why steelmakers need to be looking at data — but what exactly is the data steelmakers care about for a modern data-driven continuous casting machine?
That’s what we hope to clarify in this post. We’ll discuss:
The most important data steelmakers should be using for a modern data-driven continuous casting machine are the process parameters. These include casting speed, steel temperature, water temperature, oscillation characteristics, mold friction, mold level, etc. Collecting data on these parameters is critical for optimizing the casting process and reducing defects in the final product. Sensors installed in the continuous casting machine can capture this data and feed it into a data analytics platform for analysis.
Furthermore, data analytics platforms can also use machine learning algorithms to predict future outcomes based on past data, enabling steelmakers to anticipate issues before they occur and take corrective action proactively. This predictive modeling can be particularly useful in identifying and addressing defects in the final product — as well as predicting equipment failures that could result in costly downtime. Ultimately, the collection and analysis of data on both process parameters and other relevant variables can help steelmakers optimize their casting processes, reduce defects, and increase overall efficiency and profitability.
Another primary source of data steelmakers should be using are the material properties of the molten steel. These include chemical composition, viscosity, density, as well as the superheat temperature at the caster. Collecting data on these properties is essential for predicting the behavior of the molten steel during casting and ensuring that the final product meets quality standards.
Collecting and analyzing data on material properties of the molten steel can help steelmakers make informed decisions and adjustments during the casting process. For example, if the chemical composition of the molten steel is not consistent, it can lead to variations in the final product’s quality. By monitoring and analyzing these variations, steelmakers can adjust the process parameters, such as casting speed or mold oscillation, to compensate for the changes in material properties and ensure a consistent final product. Moreover, understanding the material properties of the molten steel can also help optimize the casting process, reducing the amount of scrap and improving the overall efficiency of the operation.
Environmental data is also a critical source steelmakers should be using to promote the best practices for modern data-driven continuous casting machine processes. This includes data on ambient temperature, humidity, and air pressure. Collecting this data is crucial for understanding how the environment affects the casting process and optimizing the process accordingly.
This data plays a significant role in the performance of the continuous casting machine. Changes in temperature, humidity, and air pressure can affect the cooling rate of the steel, which can lead to defects in the final product. For example, higher temperatures can cause the steel to cool too quickly — resulting in cracks or other imperfections.
By collecting and analyzing environmental data, steelmakers can gain insights into how to adjust the casting process to compensate for these variables and produce high-quality steel consistently. Additionally, environmental data can also help steelmakers optimize energy usage and reduce costs associated with the continuous casting process.
An essential type of data for steelmakers is the machine equipment data. This includes data on the performance of the casting machine components like oscillators, rollers, bearings, and hydraulic systems. Collecting this data is essential for predicting when maintenance is required, preventing equipment failures, and ensuring smooth operation.Collecting this type of data can be accomplished through various sensors, including vibration sensors, temperature sensors, and pressure sensors. By monitoring the machine equipment data, steelmakers can identify patterns in the data that may indicate potential problems and take corrective actions to avoid downtime and reduce maintenance costs.
Additionally, by analyzing this data, steelmakers can optimize the performance of the continuous casting machine, improve product quality, and reduce energy consumption. Therefore, integrating machine equipment data into a data analytics platform is critical for maximizing the productivity and efficiency of the continuous casting process.
Production data is also crucial for enabling a modern data-driven continuous casting process. This includes data on the production output, the yield, and the quality of the final product. Collecting this data is critical for tracking the performance of the casting process, identifying areas for improvement, and optimizing the process to meet production targets.
Collecting production data can also help steelmakers identify patterns and trends in the casting process that may affect the final product’s quality. Analyzing this data can help them optimize the casting process and make adjustments to improve the product’s consistency, reduce waste, and increase yield.
By using data analytics tools, steelmakers can also identify the root cause of any defects or issues with the final product and take corrective actions to prevent them from recurring in the future. Ultimately, utilizing production data can help steelmakers increase efficiency, reduce costs, and improve the overall quality of their products.
Kiss Technologies Can Help Steelmakers Gather Data
Data-driven technologies have revolutionized the steelmaking industry, and steelmakers are increasingly relying on data analytics to optimize the continuous casting process — and we can help with that here at Kiss Technologies.
Steelmakers should be collecting and analyzing process parameters, material properties, environmental data, equipment data, and production data to ensure smooth and efficient operation, reduce defects, and meet quality standards. By leveraging the power of data analytics, steelmakers can improve their bottom line, increase productivity, and stay competitive in the global market.
Bring real-time visibility to the casting process with Kiss Technologies’ CasterANALYTICS platform. Our team of steelmaking experts will help you store, manage, analyze, and make sense of your data. You’ll get scientific insight into your continuous casting process, arming you with the information you need to make data-based decisions.
If you’re ready to put data to work for you, Kiss Technologies has the data solutions you’re looking for. Get in touch with our team for a private presentation on how we can help you.
5 Ways to Improve Quality and Production
Learn how to identify patterns, predict quality defects, optimize productivity and make informed decisions with data analytics to enhance your continuous casting process.