利用物联网优化连铸过程中的过渡吨位
技术
- 分析与建模 - 数字孪生/模拟
- 传感器 - 液体检测传感器
适用行业
- 航天
- 消费品
适用功能
- 物流运输
- 质量保证
用例
- 制造过程模拟
- 虚拟现实
服务
- 测试与认证
关于客户
塔塔钢铁公司是世界领先的钢铁公司之一，生产多种钢铁产品。该公司主要为汽车、建筑、消费品、工程、包装、起重和挖掘、能源和电力、航空航天、造船、铁路和国防以及安全领域的客户提供服务。塔塔钢铁在 26 个国家/地区拥有制造业务，包括澳大利亚、中国、印度、荷兰、新加坡、泰国和英国。
挑战
钢的连续铸造，特别是当以相同的顺序铸造不同等级的钢时，会产生过渡钢坯。这些钢坯不符合任何特定等级，因此需要降级或转移。挑战在于确定该混合区的范围和位置，以最大限度地减少生产和质量问题。将液态钢转变为固态钢坯的方坯铸造过程充满了不确定性和变量。例如，铸造速度可能会改变，或者某些铸流可能会变得不起作用，从而改变中间包中的流量并改变过渡吨位。预测和优化不同工厂场景下品位变化期间的过渡吨位是一项重大挑战。为了更好地理解和管理这一过程，开发了 CFD 模型。
解决方案
该解决方案涉及使用 ANSYS Fluent 软件和可实现的 ke 湍流模型来模拟中间包中的流体流动。非稳态物质传输模型用于生成容器的停留时间分布。进行了进一步的数据分析以预测中间包过渡的开始和结束。 ANSYS Fluent 中强大的求解器和交互式用户界面有助于加快分析设置和后续后处理速度。模拟的准确性帮助塔塔钢铁公司优化了品位变化过程中产生的过渡吨位。这种质量控制措施减少了客户投诉并节省了过渡吨位。 ANSYS Fluent 的使用还降低了工厂规模实验和测试的成本。
运营影响
数量效益
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