Possibilities for saving energy in ferrous metallurgy: Integration of technological processes

One of the main factors having a significant effect on fuel and energy saving in the production of rolled ferrous metals is matching the operation of the continuous casting machines (CCM) with that of the reheating furnaces so called “continuous technologies” in the form of “direct rolling” or “hot charging”. In order to investigate the heat exchange processes, the opportunities for enhancing the energy efficiency and determining the optimal parameters of the flat product production process in ferrous metallurgy, some mathematical models of metal solidification and cooling in a continuous steel casting machine were determined as well as a mathematical model of metal heating in the reheating furnaces. For efficient implementation of such technologies one common algorithm was built on the basis of the individual mathematical models, representing the continuous casting - rolling mill complex control technology, dynamically matching the operation of the individual units to the actual production conditions in on-line mode. The developed algorithm can be used as part of a system for analyzing the thermal condition of the blocks at any single moment for the purpose of optimization of the units’ operation within the whole technological process. As a conclusion, considering the original developed algorithm, a 21-51% energy saving was noticed