How to achieve precise temperature control in steel ingot production?

How to achieve precise temperature control in steel ingot production?

In the process of steel ingot production, temperature control is a key factor in determining product quality. From molten steel casting to cooling and forming, the temperature changes at each stage directly affect the internal structure, mechanical properties and quality of the steel ingot. Too high a temperature may lead to coarse grains and increased segregation, while too low a temperature may cause defects such as shrinkage cavities and cracks. Therefore, achieving precise temperature control in steel ingot production has become an important breakthrough for steel companies to improve product quality and enhance market competitiveness. This requires coordinated efforts from multiple dimensions such as temperature monitoring technology, temperature control equipment, process parameter optimization and intelligent systems.

1. Use advanced temperature monitoring technology

Accurate temperature monitoring is the prerequisite for temperature control. Traditional temperature sensors such as thermocouples and thermal resistors are widely used in steel ingot production, but with the development of technology, more advanced monitoring methods continue to emerge. Infrared temperature measurement technology obtains temperature information by detecting infrared radiation energy on the surface of an object. It has the characteristics of non-contact, fast response speed, and wide temperature measurement range. It can monitor the surface temperature distribution of steel ingots in real time, and is especially suitable for high-temperature and high-speed moving steel ingots. For example, on a continuous casting production line, an infrared thermometer can quickly scan the surface of the steel billet, promptly detect abnormal temperature areas, and provide data support for subsequent temperature control.

In addition, fiber optic temperature measurement technology has shown unique advantages in monitoring the internal temperature of steel ingots due to its anti-electromagnetic interference, high temperature resistance and high precision. By pre-burying the fiber optic sensor inside the steel ingot, the temperature change data of the core of the steel ingot can be obtained in real time, helping operators to understand the distribution of the temperature field inside the steel ingot and avoid quality problems caused by excessive temperature differences between the inside and outside. Multi-sensor fusion technology is also the current development trend. It combines thermocouples, infrared thermometers, fiber optic sensors and other equipment, and uses data fusion algorithms to obtain the temperature information of the steel ingot more comprehensively and accurately.

2. Upgrade temperature control equipment and devices

The performance of the temperature control equipment directly determines the effect of temperature control. In the ingot heating process, an efficient heating furnace is the key. The new regenerative heating furnace improves energy efficiency by recovering flue gas waste heat, and adopts zoned temperature control technology to accurately heat different parts of the ingot. For example, in the heating process before forging, the heating temperature of different areas is set according to the size and material of the ingot, so that the ingot is heated evenly to avoid local overheating or insufficient heating.

In the cooling process, intelligent temperature control cooling devices play an important role. Taking the water cooling system as an example, the use of adjustable spray devices and flow control valves can accurately adjust the flow and pressure of cooling water according to the real-time temperature and process requirements of the steel ingot. When it is detected that the surface temperature of the steel ingot is too high, the system automatically increases the amount of water sprayed; when the temperature drops to a certain level, the water spray is reduced to achieve dynamic control of the cooling process. In addition, some new cooling equipment such as aerosol cooling devices can achieve precise adjustment of cooling speed and cooling uniformity by accurately controlling the mixing ratio of compressed air and water, effectively avoiding temperature abnormalities caused by improper cooling.

3. Optimize temperature control process parameters

Reasonable process parameters are the basis for precise temperature control. During the molten steel casting stage, the casting temperature, casting speed and cooling intensity need to be accurately matched. Too high a casting temperature will prolong the solidification time of the ingot and increase the probability of defects such as shrinkage and porosity; too low a temperature may lead to casting interruption or cold shut defects. By establishing a mathematical model, combined with the characteristics of the steel grade and equipment conditions, the optimal casting temperature range is calculated and dynamically adjusted according to actual production conditions.

During the cooling process, different steel grades have different requirements for cooling speed and cooling curve. For example, for high-alloy steel, in order to prevent cracks and structural defects, slow cooling is required and the temperature gradient during the cooling process is controlled; while ordinary carbon steel can be cooled appropriately. Enterprises need to formulate personalized cooling process parameters based on the composition and performance requirements of the steel grade, and strictly implement them during the production process, and continuously accumulate production data, optimize process parameters, and improve the accuracy of temperature control.

4. Introducing intelligent temperature control system

The application of intelligent technology has brought revolutionary changes to the precise temperature control of steel ingots. The intelligent temperature control system based on the Internet of Things and big data technology can integrate temperature monitoring equipment, temperature control equipment and production management system to achieve real-time data collection, transmission and analysis. The system establishes a mathematical model and prediction algorithm for the temperature change of steel ingots, predicts the future temperature change trend according to the chemical composition, size specifications and current temperature data of the steel ingots, and automatically adjusts the operating parameters of the temperature control equipment.

The application of artificial intelligence and machine learning technologies in the temperature control system enables it to have self-learning and optimization capabilities. The system continuously optimizes the temperature control strategy and process parameters by learning a large amount of production data, and improves the temperature control accuracy and stability. For example, the machine learning algorithm can analyze the relationship between the temperature change of the steel ingot and the operation of the temperature control equipment under different working conditions, automatically generate a better temperature control plan, and realize the intelligent and precise control of the temperature during the steel ingot production process.

Achieving precise temperature control in steel ingot production is a systematic project that requires the coordination of advanced temperature monitoring technology, high-performance temperature control equipment, reasonable process parameters, and intelligent control systems. Through continuous innovation and technological upgrades, steel companies can better control the temperature changes in the steel ingot production process, improve product quality, reduce production costs, and gain an advantageous position in the fierce market competition.