Use Case: Caster Optimization for Surface Defect Reduction

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items-center gap-3 mt-4"> <span class="text-blue-900">By: Fero Labs</span> <picture> <img src="data:image/svg+xml;charset=utf-8,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%2716%27%20height%3D%279%27%20style%3D%27background%3Atransparent%27%2F%3E" srcset="https://craft-ferolabs.transforms.svdcdn.com/production/logo_light.png?w=100&h=100&q=80&fm=webp&fit=crop&crop=focalpoint&fp-x=0.5&fp-y=0.5&dm=1707432360&s=1e9fe77b0d2d68709c5c76f431badd32 100w" sizes="100vw" class="w-full rounded-full max-w-[50px]" alt="Logo light" > </picture> </div> </div> <div class="flex flex-wrap flex-row items-start mt-3"> <div class="flex flex-row flex-wrap items-center"> <a href="/insights?category=steel#listing" class="transition-normal uppercase underline text-blue-900 hover:text-opacity-80 "> Steel </a> <span>, </span> <a href="/insights?category=use-case#listing" class="transition-normal uppercase underline text-blue-900 hover:text-opacity-80 ml-1"> Use case </a> </div> <div class="text-blue-900 uppercase">• April 2024</div> </div> </div> </div> <div class="w-full h-full"> <picture> <img src="data:image/svg+xml;charset=utf-8,%3Csvg%20xmlns%3D%27http%3A%2F%2Fwww.w3.org%2F2000%2Fsvg%27%20width%3D%2716%27%20height%3D%279%27%20style%3D%27background%3Atransparent%27%2F%3E" srcset="https://craft-ferolabs.transforms.svdcdn.com/production/AdobeStock_258340961.jpeg?w=2500&h=1000&q=80&fm=webp&fit=crop&crop=focalpoint&fp-x=0.5&fp-y=0.5&dm=1714429392&s=bc250456c7dfdff4dffaf6ccc77f9e25 2500w" sizes="100vw" class="w-full h-full object-cover" alt="Adobe Stock 258340961" > </picture> </div> </div> </section> <section id="content"> <section class="padding-t-small padding-b-small container"> <div class="max-w-content mx-auto"> <div class="flex flex-col lg:gap-12 lg:flex-row lg:justify-between"> <aside class="order-last lg:order-first lg:sticky lg:top-32 lg:h-min"> <div> <div class="overline-2 text-blue-500">Share</div> <ul class="flex flex-row items-center gap-4 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rich-text text-base"><h2>Use Case Description</h2><h4><strong>Background</strong></h4><p>Several steel surface defects, such as longitudinal and off-corner cracks, originate from the continuous casting process. Casting speeds and temperatures, cooling rates, and the chemical composition of different steel grades can contribute to the problem, leading to reworked or even scrapped production.</p><h4><strong>Problem</strong></h4><p>Controlling continuous casting to maintain stable production conditions while minimizing surface defects is challenging. The <strong>variability in the chemical composition</strong> of different grades of steel and equipment age, along with <strong>desired casting temperature and speed set points</strong> can lead to increased surface defect rates.</p><p><strong>Process engineers and operators</strong> in charge of continuous casting processes define set points such as casting temperatures, speeds, mould water flows and pressures to maintain high quality and stable casting of steel into semi-finished products (blooms, ingots, billets, slabs, etc.). These are set based on solidification profiles, tundish temperatures and other process parameters, and rarely reflect variations in chemistry.</p><blockquote><p>Minimize surface defects during continuous casting by adaptively controlling casting parameters on a batch-by-batch basis in real time.</p></blockquote><p>The current solution involves physics-based models and following historical best practices. These do not capture the full properties of each batch being cast. This approach leads to:</p><ul><li>financial loss due to rework and scrap of products with too many surface defects,</li><li>environmental cost of incurring Scope 1 and 2 emissions due to the unnecessary rework or scrapping of produced steel.</li></ul></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=77883" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Click here to download the entire Playbook </a> </li> </ul> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2>Fero Labs Solution</h2><p>Continuous casting process operators can use Fero Labs software to minimize surface defects by adapting to each batch and learning over time. Operating limits for caster set points can be configured within the software to enable safe recommendations that operators can follow with confidence.</p><p>A Live Fero Analysis for this use case presents two screens:</p><ul><li>Detailed View: for <strong>production engineers</strong> to monitor production and direct action plans at any moment.</li></ul><figure class="image"><img src="https://craft-ferolabs.transforms.svdcdn.com/production/Graphics/Detailed-View.png?w=2240&h=1320&auto=compress%2Cformat&fit=crop&dm=1714429738&s=9e24d8a299bcc1470bab77753a5688d5" width="1200" height="1200" alt="" /></figure><ul><li><span>Simplified View</span>: for continuous casting process <strong>operators</strong>, with critical information clearly presented.</li></ul><figure class="image"><img src="https://craft-ferolabs.transforms.svdcdn.com/production/Graphics/Simplified-View.png?w=2240&h=1162&auto=compress%2Cformat&fit=crop&dm=1714429822&s=50e2bb98dcc5f7b71c63e8babd130ea0" width="1200" height="1162" alt="" /></figure><p> </p><h2>Process & Business Outcomes</h2><p><span class="text-orange-500"><strong>Significant reduction of scrap rates</strong></span></p><p>With Fero Labs providing optimal recommendations for continuous caster parameters, chemistry and caster temperature variability no longer translate to increased surface defects. Since each batch is optimized to safely minimize surface defect rates relative to its specific chemical composition and casting temperature, continuous casters can expect a <strong>18% decrease</strong> in scrap rates.</p><p> </p><p><span class="text-orange-500"><strong>Decreased severity of surface defects</strong></span></p><p>Fero Labs software not only minimizes the probability of surface defects, but also recommends operational changes that reduce the length of surface defects. With a full adoption of Fero Labs software on the production line, continuous casters can see up to <strong>40% reduction</strong> in average surface crack lengths. Knowing that production will reliably meet its specifications leads to smoother operations.</p><p> </p><p><span class="text-orange-500"><strong>Measurable cost savings minimizing rework</strong></span></p><p>Static casting operating procedures for product grades lead to unnecessarily high surface defect rates. Some of these products can be reworked, which incurs additional rework costs, both in personnel and in energy. With a full adoption of Fero on the production line, continuous casters can expect up to <strong>15% reduction in rework</strong> of semi-finished products with mild surface defects.</p><p> </p><p><span class="text-orange-500"><strong>Commensurate Scope 1 and 2 carbon footprint minimization</strong></span></p><p>The minimization of scrapped and reworked product directly translates to a commensurate reduction of Scope 1 and 2 emissions. Since more than half of EAF steelmaking’s carbon footprint falls into Scope 1 and 2, a reduction here can reduce the carbon footprint of production by <strong>up to 10%</strong>. Fero can provide reporting capabilities that directly track and account for this reduction.</p></div> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2>Fero Labs Adoption Timeline</h2><p>Plant teams can collaborate to set up and deploy Fero Labs. Below is a timeline highlighting typical steps. With Fero’s easy-to-use, no-code interface, this can be achieved in a matter of weeks, not months or years.</p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=77883" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Download the Playbook for Timeline details </a> </li> </ul> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2>Data Requirements</h2><p>Plant teams can collaborate to set up and deploy Fero. Below is a timeline highlighting typical steps. With Fero’s easy-to-use, no-code interface, this can be achieved in a matter of weeks, not months or years.</p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=77883" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Only available in the Playbook - download now! </a> </li> </ul> </div> </div> </div> </section> <section class=" bg-white " > <div class="container padding-t-default padding-b-default"> <div class="max-w-content mx-auto"> <div class="w-full"> <div class=" text-neutral-900 rich-text text-base"><h2><span class="text-blue-500"><strong>Activating This Use Case</strong></span></h2><p>Consider our Industrial Use Case Playbooks as inspiration and tactical ideas for your team to align on to maximize the efficiencies of your plant.<br /> </p><p>Each Playbook has a matching <span class="text-blue-500"><strong>Use Case Blueprint</strong></span> which provides more detailed steps to activate each use case within the Fero Labs platform.</p><p>If you’re curious to see these in action please <a href="https://www.ferolabs.com/get-in-touch">book a free feasibility study</a> with our team!</p><p>Together, let us continue to push the boundaries of what's possible, driving towards a future where industrial manufacturing is not just efficient and sustainable but truly transformative in its impact on society and the world at large.</p><p>Thank you for joining us on this journey, and we look forward to continuing to partner with you in your pursuit of excellence.<br /><br />Download the entire <span class="text-blue-500"><strong>Caster Optimization for Surface Defect Reduction Playbook</strong></span><strong> </strong>to access additional tables and details about this industrial use case.</p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a href="https://www.ferolabs.com/index.php/actions/asset-count/count?id=77883" target="_blank" class="link text-lg font-bold underline text-orange-500 hover:text-blue-200" >Click here to download the entire Playbook </a> </li> </ul> </div> </div> </div> </section> </article> <aside class="hidden lg:block lg:sticky lg:top-40 lg:h-min"> <div class="overline-2 text-blue-500">See more insights</div> <ul class="flex flex-col gap-5"> <li> <a href="/insights?category=steel" class="text-neutral-900 transition-classes hover:text-orange-500"> Steel </a> </li> <li> <a href="/insights?category=use-case" class="text-neutral-900 transition-classes hover:text-orange-500"> Use case </a> </li> </ul> </aside> </div> </div> </section> <section class="padding-t-default padding-b-default bg-neutral-50"> <div class="container"> <div class="max-w-content mx-auto"> <div class="flex flex-col md:flex-row md:items-center md:justify-between gap-6 mb-8 md:mb-12"> 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