Continuous casting equipment and its functions

SMS II , CCP Operation

A K Karande

Continuous casting equipment

Ladle Tundish Car Tundish Mould Mould Oscillation Dummy Bar

Bender

Ladle Turret

Top Zone Cut Off Segments SMS II , CCP Operation Straightener

Discharge

A K Karande

Ladle Turret

Function: Supports the Ladle in Casting Position. Usually Fitted with Lift/Lower Arms for Ladle Covers Allows Exchange of Full and Empty Ladles Allows Sequence Casting Allows Emergency Rotation

SMS II , CCP Operation

A K Karande

Shroud manipulator

Function: Shrouding manipulator holds the refractory shroud

Protect the ladle stream and avoid the air ingress

Avoid re-oxidation of the steel Perform submerged opening

Helps to detect the slag entry with slag detector fitted on arm
SMS II , CCP Operation A K Karande

Tundish car

Tundish car
Function: Supports the Tundish.

Allows Transport of the Tundish from Pre-heat to Casting Position.

Allows Lift / Lower and Alignment of the Tundish SEN wrt mould. Allows Exchange of Tundish during Sequence Casting.

Allows Emergency Removal of Tundish.

SMS II , CCP Operation A K Karande

Tundish
Ladle Shroud Tundish Powder

Weirs

Tundish Lid

Dams

Tundish to Mould Shroud

Function: -

minimum residence time = 7 - 8 minutes

Provides a Stable Controlled Liquid Steel Feed to the Mould. Ability to act as a reservoir during ladle changeover Distribution of flow between strands Provides a Uniform Steel Temperature to Each Strand. Allows Floatation of Inclusion for Cleaner Steel. Must Minimise Heat Loss from Liquid Steel During Casting. (using tundish powder layer and tundish lid)
SMS II , CCP Operation A K Karande

Tundish Pre heaters

Functions: Moisture removal in tundish. Avoid freezes of first incoming steel of the cast. Avoid SEN choking during start of cast. Maintain ideal super heat in tundish. Avoid thermal shock to pouring refractory.

Ladle to tundish temperature drop minimized.

Smooth start of casting.
SMS II , CCP Operation A K Karande

Mould

The continuous caster mould performs several diverse functions in a integration fashion It serves as: A heat exchanger that handles a very high heat flux(>1 mw/m2). A solidification device that builds up a thin solid shell. A Die which gives its shape to the product without tearing the brittle shell. A Chemical reactor with a huge through put which separate liquid steel from non-metallic.
SMS II , CCP Operation A K Karande

HEAT TRANSFER IN CONTINUOUS CASTING

Heat transfer in mould
Heat transfer in the mould is controlled by using casting flux:

Convection of liquid super heat to the shell surface Solidification (Latent heat evolution in the mushy zone) Conduction through the solid shell The size and properties of the interface between the shell and the mould Conduction through the copper mould Convection through the mould cooling water
SMS II , CCP Operation A K Karande

HEAT TRANSFER IN CONTINUOUS CASTING

Mould cooling

Mould water transfers heat from the solidifying shell Mould cooling water flow, velocity and pressure is designed to prevent both boiling and control the mould copper temperature. Mould cooling should be as even as possible around the circumference of the mould.
SMS II , CCP Operation A K Karande

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Break out prediction and Thermal mapping

Task Solution
Prediction of stickers and reduction of break-out rate

Measured value of relevant process information Evaluation of signals under consideration of different process situation Data storage and management for analysis of critical operating conditions

SMS II , CCP Operation

A K Karande

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Mould oscillator Mould oscillator is necessary to:

Minimize friction between mold plates & steel shell

Sticking of the solidifying shell Avoid shell tearing Avoid liquid steel break outs

Oscillation Systems: Electro-mechanical (CC 1&2). Hydraulic (CC 3)

SMS II , CCP Operation A K Karande

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Conventional Mould with Four Cam Oscillator

CC 1 & 2
Fixed mould stroke

Sinusoidal wave form only

Frequency varies directly with casting speed

SMS II , CCP Operation CONVENTIONAL MOLD

K Karande RESONANCEAMOLD

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Hydraulic Mould oscillator (CC-3)

Mould fixation unit

Mould centering

Automatic mould water connections Bender support

Variable mould stroke Sinusoidal and Non sinusoidal wave forms

Mould table Weight compensator

Leaf spring guiding system

Variable frequency.

Effect of non-sinusoidal oscillation

2 Stroke [ mm ] Sinusoidal Non-Sinusoidal 1 0 -1 -2

50%
70% Normalized Time

Decrease of depth of oscillation mark Increase of mould powder consumption Decrease of frictional force between solidified shell and mould
A K Karande

SMS II , CCP Operation

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Mechanism of oscillation mark formation

SMS II , CCP Operation

A K Karande

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Auto mould level control CC 1&2

Tundish
Stopper Rod

Radiation source Scintilla. Counter Mold

hydrauliccylinder or Electro mech. actuator

SMS

Automatic functioning of casting process Constant and precise mold level

Elimination of slag entrapments Accuracy +/- 5mm Improvement of surface quality Minimization of powder usage and inclusions
SMS II , CCP Operation A K Karande

16

Auto mould level control CC 3

Mould Level Controller

Control during all casting conditions Auto start/resume cast

Accuracy 3 mm standard deviation

Backlash compensation Clogging prevention (vibration, knocking)

Measurement

Flow Control

Actuator

Electromagnetic

Stopper rod

Electric actuator
A K Karande

SMS II , CCP Operation

17

Strand support
Slab caster Bloom caster

SMS II , CCP Operation

A K Karande

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Dummy bar and systems

Function:
Plug the mould and enable start of casting.

Initiate withdrawal of the strand. Controls withdrawal until the strand enters the drive rolls.

Types:
Top fed - used on high production casters - expensive option.

Bottom fed - used on low/medium production casters - cheaper option.

Restranding Times:
Top fed - 25 minutes minimum.

Bottom fed - 45 to 60 minutes.

SMS II , CCP Operation

A K Karande

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Secondary cooling system

Secondary Cooling Options: Water only. Limited turndown. Used for less demanding steel grades. Limited cooling capacity Increased nozzle blocking tendency. Air mist. Increased turndown. Used for all steel grades including critical grades. Increased cooling capacity (maximum K-factor > 30 [slab casting]). Reduced nozzle blockage tendency.

SMS II , CCP Operation

A K Karande

20

Secondary cooling control system

Speed tie control (level 1 PLC)

Zone water flows vary directly with changes in casting speed.

Dynamic control (level 2 Computer)

Zone water flows vary with respect to the age of the strand contained within each cooling zone.

SMS II , CCP Operation

A K Karande

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Secondary cooling control system

Speed Tie Control

Dynamic Computer Control

Speed / Water Flow

Speed / Water Flow

Zone Water Flow

Zone Water Flow

Casting Speed

Casting Speed Effective Zone Speed

Time
SMS II , CCP Operation

Time
A K Karande

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Comparison of cooling systems

Speed Tie Zone Water Flow

Speed / Water Flow

Dynamic Control Zone Water Flow

Over Cooling

Under Cooling

Casting Speed

Time
SMS II , CCP Operation A K Karande

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