Predictive model for process optimization and consistent quality assurance

X-Pact® Integrated Process Model combines all processing steps from the furnace/caster to the down coiler to form a higher order temperature model. All processing steps interact and subordinate themselves to the best overall result. Disturbances and errors will be compensated by each upcoming process.

X-Pact® Integrated Process Model is able to make recommendations for appropriate responses to process variations, with the primary goal to further boost the product quality and yield. The approach guarantees maximum temperature homogeneity along the complete strip length resulting in optimum mechanical properties.

Customer challenges adressed

  • Individual process optimization does not always lead to the best overall result
  • Product quality is not achieved, down grading is possible
Each model calculates the temperature profile separately
Correlation between process steps is taken into account for requested coil material properties

The individual models’ knowledge about the process conditions within IPM are linked and coordinated to optimize the highly correlated production process. Namely the following Level 2 models are taken into account:

  • X-Pact® Solid Control (SC)
  • X-Pact® Dynamic Furnace Control (DFC)
  • X-Pact® Pass Schedule Calculation (PSC® for RM and FM)
  • X-Pact® Cooling Section Control (CSC)
  • X-Pact® Finishing Temperature Controller (FTC)

Additional objectives of the current development include additional process models the X-Pact® Microstructure Property Model (MPM) and the X-Pact® Plant Pacing to maximize the production capacity as well as decrease energy and water consumption, which results in reduced production costs.

Key features

  • Reduce production cost by optimizing temperature settings
  • Stable, highest production with homogeneous work load in each production step
  • Homogenous material properties from strip to strip
  • Adaptation will improve and adjust the production to always changing plant condition
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