Designing a casthouse for billets is a complex activity. It must becorrectly sized to optimize metal flow and continuously feed thehomogenization shop. It must also be borne in mind that oversizingadds no value and is costly. To solve this problem,casthouse operations must be analyzed accurately in real timeusing a discrete simulation model. Such a model was developed,with a library containing all the necessary equipment: conveyors,continuous and batch furnaces, and finishing stations.The model was used to design a fully integrated casthouse,requiring flexible, robust facilities and management of complexproduct mixes. By combining this model with the metal-flow sizingmodel, design execution and its impact on casthouse operationwas optimized. The result is a shop designed for customer needs,at optimal cost.
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