LevCon: Mold Level Control System for Enhanced and Efficient Casting Operation

LevCon is a mold level control system designed to optimize continuous casting operations in the steel industry. Steel producers face challenges such as maintaining high-quality production with minimal defects, ensuring consistent operations, and enhancing safety while reducing downtime. LevCon addresses these challenges by increasing operational safety through automatic start procedures and dynamic parameter adaptation. It effectively reduces the impact of varying flow conditions and unsteady bulging effects using advanced model-based control algorithms. With compatibility across all major measuring systems, LevCon ensures seamless integration and superior performance.

LevCon enables fast and reliable mold level control by automatically adapting to changing casting conditions and proactively compensating for disturbances using advanced model-based algorithms. Combined with precise SEN flow regulation and robust mechanical components, the system improves process stability, enhances safety, and supports highly automated casting operations.

Anti-Bulging Solution for Continuous Casters

In slab casting, the bulging compensation algorithm counteracts flow oscillations from the liquid core by modulating steel flow through stopper movements in the SEN. For ESP lines, Anti-Bulging uses the LevCon Bender to regulate steel inflow into the mold and maintain a stable level. This includes a mathematical model of the level disturbance generated by unsteady bulging, which depends on casting speed and roller pitches in the bulging-sensitive zone. Reliably estimating this disturbance allows for effective compensation. This feature consistently suppresses mold level fluctuations caused by unsteady bulging, producing a smoother strand shell.

The Benefits of LevCon’s Anti-Bulging Feature Include

• Improved production flexibility and increased throughput with higher casting speeds or varied cooling patterns
• Quick return on investment through quality improvements and increased production
• Enhanced slab quality for sensitive steel grades prone to bulging
• Detects only actual bulging and does not respond to unrelated disturbances such as flow irregularities

Mold Level Report

If you are unsure which LevCon modules are necessary to improve your mold level and product quality, request a Mold Level Report. We will analyze your data and tell you how much you can improve with LevCon. Since the analysis is done remotely, it saves you valuable time. The evaluation report includes diagrams, solution suggestions, and descriptions of problems and causes.

Benefits of the Caster Mold Level Control System LevCon

• Improves steel quality through adaptive mold-level control and Anti-Bulging technology
• Increases plant reliability and overall casting productivity
• Enhances operational safety with automatic start procedures and AutoStart
• Reduces downtime with fast emergency support and reliable system performance
• Compensates for bulging and clogging effects during casting
• Dynamically adjusts control parameters based on casting conditions
• Reduces SEN wear and maintenance requirements
• Compatible with major electromagnetic and radiometric measuring systems
• Modular and expandable design for easy integration into existing casters