Process Engg > Tools > SecSim (Secondary Steelmaking Simulator)
SecSim (Secondary Steelmaking Simulator)

About the simulator

The nature and type of the steel depends mainly on the conditions and processes imposed on the molten metal during the secondary steelmaking process. The challenge begins with identifying the right parameters to enable the process you follow (Ladle/Tundish) to run at an optimum performance level. Studying the suitability of process and design changes, arriving at the process parameters for optimized plant performance and understanding flow behavior under changed conditions are imperative to developing high quality steel.. However, experimenting with varied processes and designs while arriving at the best parameters, can affect productivity and plant performance.

TCS understands the challenges involved in secondary steelmaking, whatever your manufacturing process.  Using a software tool for multivariable optimization, our solution seamlessly introduces suitable process and design changes without productivity loss.   Our team of experts gathers data from your existing operations and simulates the process using varied parameters to understand the behavior under changed conditions, and then obtains process parameters for optimized plant performance. Our solution also provides a detailed temporal thermal analysis of secondary steelmaking operation.

Model Considerations

Fluid Flow due to forced and natural convection

Convective/conductive transport in the melt/ refractory

Heat loss/gain due to additions and arcing

Heat losses from refractory and top

Model Outputs

Flow pattern during purging, holding and teeming

Thermal profiles in metal and refractory

Time required for thermal homogenization

Quantification of heat gain/loss due to arcing, additions and purging


Identifying the optimum plant performance level parameters for the secondary steelmaking process, our simulator helps you in the following ways:

  • Quantification of heat gain/loss due to arcing, additions and purging

  • Performance of Virtual Simulator: Prediction of steel temperature within ± 5 oC from OLP to Teeming

  • Platform for building control model (LFOR)

  • Tighter control of steel temperature based on process sensitivity analysis

  • Better temperature and chemistry sampling in ladle furnace based on predicted bath homogenisation time of 3 minutes

  • The CFD-based simulator is an off-line analysis tool of ladle furnace and it will be used for process analysis and identification of vital process parameters leading to quality and productivity improvements from better control of superheat