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The Iron & Steel Technology Conference and Exposition 2010
(AISTech 2010)

 

Mill Level 2 Model in Improvement of Product Quality and Productivity

Bingji (Benjamin) Li
www.metalpass.com/bli
Metal Pass LLC
www.metalpass.com
Pittsburgh, PA, USA
 

Key words: Level 2 Model, draft schedule, product property, shape defect, productivity, rolling mill models
 

ABSTRACT

Mill Level 2 model, with major manufacture logics and mill intelligence in it, is responsible for creating draft schedule and stage plan. Level 2 model errors would cause equal deformation target, metallurgical temperature target and maximal productivity target, etc. to be missed. This paper first discusses association of Level 2 model quality with product property and shape and mill productivity. Then it covers application of a full range of rolling mill models in Level 2, and integration of models on product defects (camber, center/edge wave, etc.) with Level 2 and AGC. Examples are from author’s past and ongoing consulting projects.
 

CONTENTS


1 MAJOR SUCCESS FACTORS IN MILL OPERATION

Development of New Grades
Metallurgical Scheduling
Hardware
Functional and Accurate Level 2 System
Production of High-Strength Steels

2 EFFECT OF LEVEL 2 ACCURACY ON PRODUCT QUALITY AND PRODUCTIVITY

Product Defects due to Missing Production Targets
- Equal Deformation Target
- Metallurgical Temperature Target
- Mill Capacity and Productivity Target

Draft Scheduling vs. Level 2 Model
- Draft Scheduling Constrains
- Roll Deformation and Temperature Accuracy Issues
- Strip Mill Level 2

Significance of Accurate Level 2 Force Prediction

Benefits of Metallurgical Level 2 Model
- High Accuracy of the Force Prediction
- Improved Pass Schedule and Slab Selection

3 LEVEL 2 MODEL IMPROVEMENT

Sources of Level 2 Model Error
- Common Sources of Level 2 Model Error
- Flow Stress Learning Issues and Logic Error
- Other Parameter Errors

Level 2 Model Accuracy Improvement
- General Work Procedures
- Application of a Full Range of Mill Models
- Improvement of Level 2 Force Prediction – Steckle/Plate Mill

Draft Schedule Improvement Examples
- General Improvement for Draft Schedule
- Plate Mill Draft Scheduling (1) – Metallurgical Integration
- Plate Mill Draft Scheduling (2) – Use of Metallurgical Model
- Strip Mill Level 2


 


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