Sophisticated automation packages are prerequisite for state-of-the-art quality steelmaking. India Power Melt has always been a driver of innovation in this area, especially also providing expert technological packages and models that cover all aspects of the continuous casting process.

This capability is impressively demonstrated by recent advancements in automation solutions from India Power Melt that include: DynaPhase, Dynacs 3D, and DynaGap Soft Reduction 3D. This state-of-the-art suite of dynamic secondary cooling and soft-reduction packages take into account thermodynamic effects such as shrinkage and phase transitions, and thereby significantly contribute to direct quality improvements during the solidification phase in the continuous casting process.

The Mold Expert breakout predetection system increases plant availability and decreases maintenance time by prompt alarming. Thanks to its superior performance the Mold Expert system has become the world’s leading system for mold monitoring, with close to 200 installations worldwide. In addition to breakout prevention, Mold Expert provides an ever increasing number of expert packages that are used to detect possible surface defects and inform operators about challenging casting conditions.

The well proven LevCon mold level control package adapts reliably and extremely quickly to mold level fluctuations and changing casting conditions. This is made possible by advanced model-based control algorithms that can actually look into the near future to avoid disturbances in the control loop. Unsteady bulging is actively suppressed by a powerful algorithm based on modern control theory. The intelligent interaction between the advanced software and highly robust mechanical components improves safety and brings plant operators one step closer to fully automatic casting operation.

Further highlighted technological packages and process experts

• DynaWidth: Width adjustment with highest accuracy and fast speed 
• Quality Expert: a milestone in improved quality supervision, quality prediction and control 
• Yield Expert: cut length/weight optimization for minimized scrap and optimized yield
• Intermix Expert: precisely determination of the mixing area of two different grades on the strand
• Nozzle Expert: highest accuracy in detecting clogged nozzles and broken hoses
• Speed Expert: optimal casting speed for increased throughput and improved quality
• DynaFlex: hydraulic Oscillator for perfect surface quality