An online monitoring system for mould processes would not only provide early alarms for potential breakouts but also prevent casting defects in the downstream processes. Identification of aberrations in the solidification process of steel inside the mould would make information available for immediate problem analysis & prevention and would aid continuous quality improvement.
Casting is a critical step in steel making. Conversion of molten steel into slabs while casting may lead to spill out of molten steel around the mould bottom. This phenomenon is known as breakout. Breakouts can cause the damage of the caster ,loss of production and poor safety records.
To prevent breakouts, Automation Division, Tata Steel has developed a Casting Online Diagnostics System (CODS). Breakouts can be detected while the molten steel is inside the mould .It has been observed that 90% of the breakouts happen due to sticker and such breakouts are known as sticker breakouts.
Casting Online Diagnostics System (CODS) reads the temperature signals from an array of thermocouples embedded in the mould horizontally in four layers. It is able to predict the tendency towards the sticking of solidifying shell inside the mould and take automatic preventive action when necessary. It also reads the non TC field inputs and provides indication of the casting health with a continuous performance indicator called "Breakoutability".