Switched MPC Based on Clogging Detection in Continuous Casting Process

Nozzle clogging contributes heavily to quality issues seen during the process of continuous casting. The presence of clogging in the Submerged Entry Nozzle (SEN) can significantly change the flow patterns in the mould and therefore impact the quality of the steel product. Also, there is a high risk of inclusions due to parts of the clogging material breaking off and entering the mould. In this paper, we propose a new sensor setup that allows us to detect clogging in the SEN by monitoring the angle of the exiting jet. Based on this clog detection setup, a switched MPC controller is used to keep the angle of the exiting jet between the optimum ranges using an Electromagnetic Brake. This allows the controller to keep the angle of the jet in the optimum range even when clogging occurs in the nozzle. Experimental data from a laboratory scale continuous caster is used to derive the models for the controller.