1 Introduction to Process Modeling in Steel Industry

1.1 Industrial Trend – Modeling – Computer Applications
1.2 Empirical Models
1.3 Numerical Approaches

2 Empirical Models

2.1 Flow stress

    2.1.1 Flow Stress
    2.1.2 Modeling of flow stress

2.2 Force and Power Requirements during Rolling

    2.2.1 Force and Shape factor
    2.2.2 Modeling of Shape Factor
    2.2.3 Modeling of the Torque and Power

2.3 Metal Flow during Rolling

    2.3.1 Spread and Reduction

        2.3.1.1 Spread influence factor (incl. Simple empirical eq.)
        2.3.1.2 Shinokura
        2.3.1.3 Hensel
        2.3.1.4 BL Extension
        2.3.1.5 Ekelund
        2.3.1.6 Wusatowski

    2.3.2 Forward Slip and Speed
    2.3.3 Tension Correction for Spread and Forward

2.4 Temperature during Heating, Rolling and Controlled Cooling

    2.4.1 Reheating
    2.4.2 Rolling
    2.4.3 Controlled water cooling
    2.4.4 Controlled Air Cooling

2.5 Crown and Strip Flatness

    2.5.1 Crown
    2.5.2 Roll Deflection
    2.5.3 Roll Thermal Model and Roll Cooling
    2.5.4 Roll Wear

2.6 Microstructure and Product Property during and after Rolling

    2.6.1 Microstructure Process during reheating, rolling and cooling
    2.6.2 Dynamic Recrystallization
    2.6.3 Static Recrystallization
    2.6.4 Grain Growth
    2.6.5 Retained Strain during Warm Rolling

    2.6.6 Prediction of Rolled Product Properties

        2.6.6.1 Tensile Strength
        2.6.6.2 Yield Strength
        2.6.6.3 Others

    2.6.7 Model Application

        2.6.7.1 Draft Schedule Improvement
        2.6.7.2 Low-Cost Slab Selection

2.7 EAF/LMF Steelmaking

2.8 Casting

3 Numerical Approaches

3.1 Finite Differential Method

3.2 Finite Element Method

    3.2.1 Model

        3.2.1.1 Numerical Approach
        3.2.1.2 Boundary Conditions
        3.2.1.3 Model Verification/Improvement

    3.2.2 Metal Flow
    3.2.3 Power and Force
    3.2.4 Temperature
    3.2.5 Temperature in EAF/LMF
    3.2.6 Casting

3.3 FEM Simulation of Shape Rolling - A Real World Project

4 High-Temperature Properties of Metals and Steels

4.1 Mechanical
4.2 Thermal

5 Fussy-Logic, Neural-Network and Intelligent Learning

5.1 Fussy-Logic Rules
5.2 Neural-Network, Direct Modeling
5.3 Neural-Network, Hybrid Solution
5.4 Expert System

6 Introduction to Computer Applications in Steel Industry

6.1 Automation and Competitiveness of Steel Industry
6.2 Automation and Computer Integration – A Short Review
6.3 A Short Summary on Level 2 History
6.4 History of CIM in Steel Industry
6.5 Web-Based Application
6.6 Other Related Topics
6.7 Some Points with Software Engineering

7 Technical Review on the Computer Integration

7.1 Computerized Process Control System
7.2 Automatic Gauge Control
7.3 Multi-Level Automation – The Past, Present And Future
7.4 Evolution of Computer Control System Architectures
7.5 Neural Network

    7.5.1 Introduction
    7.5.2 Application in Steel Mill

7.6 Fuzzy Logic and Control

    7.6.1 Introduction
    7.6.2 Application in Steel Mill

7.7 OPC Industry Standard
7.8 Imaging Technology and Surface Examination
7.9 Three-Tier Architecture and Web-Based Systems
7.10 Shop Computer Setup Issues

8 Computer Integrated Automation Systems in Steel Industry

8.1 Overview of Computer Control In Various Steel Mills
8.2 Level 1 Systems

8.3 Meltshop Level 2 Systems

8.3.1 EAF/LMF Level 2 System
8.3.2 Caster Level 2 System

8.4 Rolling Mill Level 2 Systems

    8.4.1 Reheating Furnace Level 2
    8.4.2 Level 2 System for Hot Reversing/Steckel Mills
    8.4.3 Level 2 System for Hot Strip Mills
    8.4.4 Level 2 System for Rod and Bar Mills
    8.4.5 Level 2 System for Heavy Section Mills
    8.4.6 Level 2 System for Controlled Cooling Process
    8.4.7 Level 2 System for Cold Strip Mills
    8.4.8 Coil Tracking and Maintenance Management

8.5 Level 3 Systems

    8.5.1 Level 3 Scheduling (Mill Scheduling)
    8.5.2 Slab Providing and Slab Optimizing for Cost Reduction
    8.5.2 Level 3 Reporting

9 Implementation of Level 2 Systems

9.1 General Structure and Layout

    9.1.1 Network
    9.1.2 PLC Data Collection & Level 1
    9.1.3 Database
    9.1.4 General Function of each Sub-Systems
    9.1.5Furnace/CAS/RM or EAF/LMF/CAS/RM
    9.1.6 L2 Monitor

9.2 Level 2 Learning Model

    9.2.1 Adaptive Learning Model

        9.2.1.1 Short-Term Correction
        9.2.1.2 Long-Term Learning
        9.2.1.3 Flow Stress Model Adaptation
        9.2.1.4 Torque Model Adaptation
        9.2.1.5 Temperature Model Adaptation

    9.2.2 Neural Network and Fuzzy Logic

9.3 Level 2 System for Meltshop

    9.3.1 Scheduling
    9.3.2 Interface to PLC
    9.3.3 Data Manager
    9.3.4 Heat Tracking System
    9.3.5 Interface to Database Server
    9.3.6 Interface to Labs (Chemical and Mechanical)
    9.3.7 Inter-Application Server (EAF-LMF-CAS)
    9.3.8 Process Modeling

9.4 Level 2 System for Hot Reversing Mills for Plate and Coil

    9.4.1 Edge Setup and Learning

        9.4.1.1 Setup
        9.4.1.2 Learning
        9.4.1.3 Modes
        9.4.1.4 Edging Strategy and Rules
        9.4.1.5 Edger Physical Parameters

    9.4.2 Controlled Rolling Model

        9.4.2.1 Controlled Rolling
        9.4.2.2 Two-Slab Rolling

    9.4.3 Shape Model
    9.4.4 Mill Deflection Model

    9.4.5 Work Roll Thermal and Wear Models

        9.4.5.1 Roll Thermal Growth
        9.4.5.2 Roll Wear

    9.4.6 Work Roll Bending Model

        9.4.6.1 General
        9.4.6.2 Bending Setup

    9.4.7 Leveler Setup and Learning

9.5 Level 2 System for Hot Strip Mills

    9.5.1 Rolling Process Control
    9.5.2 Roughing Mill Setup
    9.5.3 Roughing Mill Width Control
    9.5.4 Finishing Mill Setup
    9.5.5 Strip Gauge Setup and Control
    9.5.6 Finishing Mill Exit Temperature Control
    9.5.7 Coiling Setup
    9.5.8 Coiling Temperature Control

9.6 Level 2 System for Cold Strip Mills

    9.6.1 Thickness Control for Reversing Cold Rolling
    9.6.2 Thickness Control for Continuous Cold Rolling
    9.6.3 Feed-Forward Control
    9.6.4 Mass Flow Control
    9.6.5 Other Related Topics

9.7 Level 2 System for Controlled Cooling

    9.7.1 Overview
    9.7.2 Cooling Models
    9.7.3 Subsystems

        9.7.3.1 Overview and Data Flow
        9.7.3.2 Cooling Setup Modulus
        9.7.3.3 Cooling Control Modulus
        9.7.3.4 Spray Sequencer
        9.7.3.5 Setup Request Sequencer
        9.7.3.6 Input Data Sequencer
        9.7.3.7 Logging Task

9.8 Further Development Issues for the Level 2 System

    9.8.1 Metallurgical Issues (Selected Topics)
    9.8.2 Modeling Issues (Selected Topics)
    9.8.3 Software Engineering Issues (Selected Topics)
    9.8.4 Other Issues
    9.8.5 Next-Generation Level 2 System (Selected Topics)

9.9 Level 1, Level 2 and Level 3 Data Exchange

    9.9.1 Level 1 and Level 2 Data Exchange
    9.9.2 Level 2 and Level 3 Data Exchange

9.10 Web-based Level 2/Level 3 System

    9.10.1 Web-based Mill Diagnosis
    9.10.2 Web-based Mill Level 2 Model
    9.10.3 Web-based Mill Level 2 Management System
    9.10.4 Web-based Slab-Providing

10 Miscellaneous Applications

10.1 Roll Pass Design Software

    10.1.1 Requirements: Mechanical, Temperature and Microstructure
    10.1.2 Introduction to collected packages
    10.1.3 A New approach

10.2 Roll Management

    10.2.1 Introduction
    10.2.2 Wire, Rod, Bar and combined mills
    10.2.3 Flat Mills
    10.2.4 Three-Roll Mills

10.3 Laboratory Automation Systems

10.4 Web-Based Applications - A Collection