板坯连铸二次冷却过程仿真及工艺优化
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摘要
连铸过程的二冷控制是稳定和提高铸坯质量的关键环节。准确把握连铸坯传热／凝固进程,实时、合理调控连铸坯二冷工艺,是高效连铸技术对于过程控制的基本要求,围绕铸坯二次冷却的数值计算、工艺优化、过程检测等理论与技术方法进行研究,具有重要的理论意义和应用价值。
首先,以板坯连铸为研究对象,依据铸坯传热与凝固基础理论,建立板坯连铸传热／凝固数值计算模型,开发出基于OpenGL的二冷数值仿真可视化系统。通过对不同生产工艺下铸坯凝固进程的模拟仿真,直观清晰呈现铸坯冷却历程,细致了解和掌握铸坯传热与凝固状态。仿真可视化系统的开发和应用为二冷水量的设计与优化提供可靠手段。
其次,针对国内某钢厂宽厚板坯连铸机辊列结构布置特点,依据钢种目标温度和冶金准则设计二次冷却工艺,并应用开发的连铸坯二冷数值仿真可视化系统,对铸坯的凝固进程进行仿真分析,验证二冷工艺制度的合理性。探讨了铸坯凝固进程对各工艺参数的响应特性,比照和考察三类典型钢种的凝固和传热行为。
再次,鉴于边界条件对铸坯凝固传热计算的重要性,依据反问题优化理论,建立了基于实测反问题的连铸二冷换热系数计算模型。提出根据铸坯表面温度现场实测数据,采用非线性估算法反算二冷各区换热系数的模型和方法,并通过铸坯表面温度检测和射钉实验验证模型的准确性。
然后,以统筹和兼顾冶金准则、二冷水量、铸坯表面温度等为目标,提出了一种基于变异算子改进粒子群算法的二冷工艺制度优化方法。设计了考虑包括目标温度、温度限制、温升／温降速率、鼓肚限制和冷却水量等冶金准则的价值函数,以合金中碳钢宽厚板坯为对象,采用PSO、CFPSO、MOPSO三种算法,对优化后的二冷水量、铸坯表面温度与算法效率进行分析和讨论。
最后,针对铸坯凝固进程在线检测方法进行探索,提出了“振动法”检测连铸坯凝固分数的新方法。基本原理是在铸坯表面施加一定频率和幅度的周期受迫振动,借助振动在液相、固相传递过程中不同的阻尼衰减,根据激振力和受迫振动位移等信号反馈的规律性差异,探测铸坯凝固进程,达到精确预报铸坯液固相分数的目的。在理论解析的基础上,建立凝固分数在线检测数学模型,设计和搭建物理模拟实验系统,同时采用液-固耦合受迫振动有限元计算模型对受迫振动的动态响应进行仿真,并提出检测方法的现场应用建议。研究结果为铸坯凝固进程在线检测方法开发提供理论基础。
Secondary cooling control technology is the key factor for stabilizing and enhancing slab quality in continuous casting process. Accurate description of heat transfer/solidification process and real-time and reasonable control of secondary cooling are the basic requirements for high efficient continuous casting. Therefore, the researches aiming at more accurate understanding the process such as methodologies of numerical calculation about slab secondary cooling, technology optimization and process detection have momentous theoretical significances and practical values.
Firstly, taking continuous casting slab as research object, the paper establishes slab heat transfer/solidification calculation model and develops the secondary cooling numerical simulation and visualization system for continuous casting slab using OpenGL based on the characters of slab heat transfer and solidification. By simulating the slab solidification process under different technological parameters, the slab cooling process is presented directly and clearly to gain detailed information on slab heat transfer/solidification state. The development and application of numerical simulation system provide reliable approach for control and optimization of secondary cooling water volume.
Secondly, according to the target temperature of steel and metallurgy criterion, the secondary cooling technology is designed based on roller configuration and distribution of the heavy plate caster in a domestic steel plant. On the ground of the development of secondary cooling numerical simulation and visualization system, the simulation analysis of slab solidification process is conducted, and the rationality of technology system is validated. The response characteristics of solidification process influenced by technological parameters are discussed, and the solidification and heat transfer behaviors of three typical steel grades is compared and investigated.
Thirdly, considering the importance of boundary conditions for slab solidification and heat transfer calculation, and basing on the inverse problem optimization theory, the secondary cooling heat transfer coefficients calculation model by means of inverse problem with temperature measurement is developed. According to the measured data of slab surface temperature, nonlinear estimation method is utilized to inverse calculate the heat transfer coefficients of secondary cooling zones, and slab surface temperature detection and pin-shooting experiment are applied to verify the accuracy of the developed model.
Further, by aiming at overall consideration of metallurgy criterion, secondary cooling water volume and slab surface temperature, the paper proposed a secondary cooling technology optimization method based on modified Particle Swarm Optimization (PSO) algorithm by introducing the mutation operator. In the algorithm, the cost function is designed by co-considering the metallurgy criterions of target temperature, temperature restrictions, temperature increasing/decreasing rate, bulging control and water volume. Selecting the heavy plate of alloy medium carbon steel as research object, three approaches including PSO, CFPSO and MOPSO algorithm are used to analyze and discuss the optimized secondary cooling water volume, slab surface temperature and algorithm efficiency.
Finally, the paper researches the online detection method of slab solidification process, and a new method named vibration method for detecting slab solid fraction and solidification process is presented. Its principle is by imposing a periodical forced vibration with certain frequency and amplitude on slab surface, the solidification process could be detected real-timely according to the discrepancy patterns of the feedback signals of exciting force and forced vibration displacement due to the different damping attenuation of vibration in liquid and solid phase transfer process. Therefore, the purpose of accurate prediction of slab liquid-solid fraction and the final solidifying end position could be accomplished accordingly. On the ground of theoretical derivation, the paper establishes the model for online detecting solid fraction. The physical simulating experiments, finite element calculation model of liquid-solid coupling forced vibration are developed in order to simulate and verify the results of dynamic response. And the suggestion for applying the method to a plant is proposed. The results of this research provide theoretical foundation for the detection method of online direct measurement of slab solidification process.
首先,以板坯连铸为研究对象,依据铸坯传热与凝固基础理论,建立板坯连铸传热／凝固数值计算模型,开发出基于OpenGL的二冷数值仿真可视化系统。通过对不同生产工艺下铸坯凝固进程的模拟仿真,直观清晰呈现铸坯冷却历程,细致了解和掌握铸坯传热与凝固状态。仿真可视化系统的开发和应用为二冷水量的设计与优化提供可靠手段。
其次,针对国内某钢厂宽厚板坯连铸机辊列结构布置特点,依据钢种目标温度和冶金准则设计二次冷却工艺,并应用开发的连铸坯二冷数值仿真可视化系统,对铸坯的凝固进程进行仿真分析,验证二冷工艺制度的合理性。探讨了铸坯凝固进程对各工艺参数的响应特性,比照和考察三类典型钢种的凝固和传热行为。
再次,鉴于边界条件对铸坯凝固传热计算的重要性,依据反问题优化理论,建立了基于实测反问题的连铸二冷换热系数计算模型。提出根据铸坯表面温度现场实测数据,采用非线性估算法反算二冷各区换热系数的模型和方法,并通过铸坯表面温度检测和射钉实验验证模型的准确性。
然后,以统筹和兼顾冶金准则、二冷水量、铸坯表面温度等为目标,提出了一种基于变异算子改进粒子群算法的二冷工艺制度优化方法。设计了考虑包括目标温度、温度限制、温升／温降速率、鼓肚限制和冷却水量等冶金准则的价值函数,以合金中碳钢宽厚板坯为对象,采用PSO、CFPSO、MOPSO三种算法,对优化后的二冷水量、铸坯表面温度与算法效率进行分析和讨论。
最后,针对铸坯凝固进程在线检测方法进行探索,提出了“振动法”检测连铸坯凝固分数的新方法。基本原理是在铸坯表面施加一定频率和幅度的周期受迫振动,借助振动在液相、固相传递过程中不同的阻尼衰减,根据激振力和受迫振动位移等信号反馈的规律性差异,探测铸坯凝固进程,达到精确预报铸坯液固相分数的目的。在理论解析的基础上,建立凝固分数在线检测数学模型,设计和搭建物理模拟实验系统,同时采用液-固耦合受迫振动有限元计算模型对受迫振动的动态响应进行仿真,并提出检测方法的现场应用建议。研究结果为铸坯凝固进程在线检测方法开发提供理论基础。
Secondary cooling control technology is the key factor for stabilizing and enhancing slab quality in continuous casting process. Accurate description of heat transfer/solidification process and real-time and reasonable control of secondary cooling are the basic requirements for high efficient continuous casting. Therefore, the researches aiming at more accurate understanding the process such as methodologies of numerical calculation about slab secondary cooling, technology optimization and process detection have momentous theoretical significances and practical values.
Firstly, taking continuous casting slab as research object, the paper establishes slab heat transfer/solidification calculation model and develops the secondary cooling numerical simulation and visualization system for continuous casting slab using OpenGL based on the characters of slab heat transfer and solidification. By simulating the slab solidification process under different technological parameters, the slab cooling process is presented directly and clearly to gain detailed information on slab heat transfer/solidification state. The development and application of numerical simulation system provide reliable approach for control and optimization of secondary cooling water volume.
Secondly, according to the target temperature of steel and metallurgy criterion, the secondary cooling technology is designed based on roller configuration and distribution of the heavy plate caster in a domestic steel plant. On the ground of the development of secondary cooling numerical simulation and visualization system, the simulation analysis of slab solidification process is conducted, and the rationality of technology system is validated. The response characteristics of solidification process influenced by technological parameters are discussed, and the solidification and heat transfer behaviors of three typical steel grades is compared and investigated.
Thirdly, considering the importance of boundary conditions for slab solidification and heat transfer calculation, and basing on the inverse problem optimization theory, the secondary cooling heat transfer coefficients calculation model by means of inverse problem with temperature measurement is developed. According to the measured data of slab surface temperature, nonlinear estimation method is utilized to inverse calculate the heat transfer coefficients of secondary cooling zones, and slab surface temperature detection and pin-shooting experiment are applied to verify the accuracy of the developed model.
Further, by aiming at overall consideration of metallurgy criterion, secondary cooling water volume and slab surface temperature, the paper proposed a secondary cooling technology optimization method based on modified Particle Swarm Optimization (PSO) algorithm by introducing the mutation operator. In the algorithm, the cost function is designed by co-considering the metallurgy criterions of target temperature, temperature restrictions, temperature increasing/decreasing rate, bulging control and water volume. Selecting the heavy plate of alloy medium carbon steel as research object, three approaches including PSO, CFPSO and MOPSO algorithm are used to analyze and discuss the optimized secondary cooling water volume, slab surface temperature and algorithm efficiency.
Finally, the paper researches the online detection method of slab solidification process, and a new method named vibration method for detecting slab solid fraction and solidification process is presented. Its principle is by imposing a periodical forced vibration with certain frequency and amplitude on slab surface, the solidification process could be detected real-timely according to the discrepancy patterns of the feedback signals of exciting force and forced vibration displacement due to the different damping attenuation of vibration in liquid and solid phase transfer process. Therefore, the purpose of accurate prediction of slab liquid-solid fraction and the final solidifying end position could be accomplished accordingly. On the ground of theoretical derivation, the paper establishes the model for online detecting solid fraction. The physical simulating experiments, finite element calculation model of liquid-solid coupling forced vibration are developed in order to simulate and verify the results of dynamic response. And the suggestion for applying the method to a plant is proposed. The results of this research provide theoretical foundation for the detection method of online direct measurement of slab solidification process.
引文
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