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    Billet Continuous Caster

    Uploaded by

    ziad
    The document summarizes the key components and process of a continuous billet caster. It includes: 1) The caster was installed in 2010, can produce up to 180 tonnes/hour of low and medium carbon steel billets between 8-12m in length. 2) Main components include a ladle turret, tundish, mold, spray chamber, withdrawal rolls, torch cutter, and cooling bed. 3) The process involves pouring molten steel from a ladle through the tundish into the mold, where it undergoes primary solidification. It then moves through spray cooling and cutting before final cooling and storage.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Billet Continuous Caster

    Uploaded by

    ziad
    230 views17 pages
    The document summarizes the key components and process of a continuous billet caster. It includes: 1) The caster was installed in 2010, can produce up to 180 tonnes/hour of low and medium carbon steel billets between 8-12m in length. 2) Main components include a ladle turret, tundish, mold, spray chamber, withdrawal rolls, torch cutter, and cooling bed. 3) The process involves pouring molten steel from a ladle through the tundish into the mold, where it undergoes primary solidification. It then moves through spray cooling and cutting before final cooling and storage.

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    The document summarizes the key components and process of a continuous billet caster. It includes: 1) The caster was installed in 2010, can produce up to 180 tonnes/hour of low and medium carbon steel billets between 8-12m in length. 2) Main components include a ladle turret, tundish, mold, spray chamber, withdrawal rolls, torch cutter, and cooling bed. 3) The process involves pouring molten steel from a ladle through the tundish into the mold, where it undergoes primary solidification. It then moves through spray cooling and cutting before final cooling and storage.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    230 views17 pages

    Billet Continuous Caster

    Uploaded by

    ziad
    The document summarizes the key components and process of a continuous billet caster. It includes: 1) The caster was installed in 2010, can produce up to 180 tonnes/hour of low and medium carbon steel billets between 8-12m in length. 2) Main components include a ladle turret, tundish, mold, spray chamber, withdrawal rolls, torch cutter, and cooling bed. 3) The process involves pouring molten steel from a ladle through the tundish into the mold, where it undergoes primary solidification. It then moves through spray cooling and cutting before final cooling and storage.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 17

    Billet

    Continuous
    Caster
    Awareness
    Orientation

    1
    Billet Caster main data

    Started at 2010
    DANIELLI design
    6 strands –High Speed
    Caster Machine
    Productivity up to 180
    ton/hr
    Section size 130 mm
    Product length 8-12 m
    Steel grades low and
    medium carbon steel
    2
    Location of Billet caster

    Between MS and Rolling mill Production


    Planning
    Input material is molten steel
    and out put is high quality cold Melt
    QC
    billets for rolling mill. shop

    Electrical Maintenance & Continuous


    Casting
    Mechanical Maintenance are
    main partners in the Area.
    EM MM

    Rolling
    Mill

    3
    Material Flow

    4
    Main components-Ladle turret
     To switch the ladle
    between melting
    bay and caster.
     To hold the ladle in
    casting position.
     For sequence
    casting and faster
    ladle change over
    ladle turret is used.
     Its Capacity
    support two ladles
    filled with steel.
    5
    Main components-Tundish car & Tundish

     It is necessary to
    teem steel from the
    ladle in to the mold
    via tundish.
     It Regulates the
    flow of metal into
    mold.
     Tundish allows
    sequence casting
    ladle after ladle
    6
    Main components- Mould

     Heart of continuous casting


    machine
     Responsible for primary
    solidification of the steel shell.
     Highly affects productivity and
    quality.
     Mold assembly contains the
    copper tube or plate which is
    cooled by indirect (Primary)
    water.
    7
    Main components- Spray cooling and cooling
    chamber
     Complete the rest of strand
    solidification after mold.
     Consists of multiple loops
    for better control.
     Direct water is used.
     The whole area is
    contained in steel structure
    ( cooling chamber).

    8
    Main components- Withdrawal unit
     Extract strand from machine
     Strand straightening .
     Driven rolls pull the strand
    and press it with certain
    force.
     Responsible for casting speed.
     The casting speed either
    controlled individually as set
    point or related to mold level
    as a closed loop
    9
    Main components- Torch Cutter
     The solidified strand is cut
    into certain length
    according to the customer
    requirement.
     Cut to length is performed
    either by oxy-fuel torch or
    by shear (EFS uses Torch
    cutting).
     Endless rolling now
    becomes a reality.
    10
    Main components- Discharge area & cooling
    bed
     Discharge area is used to transfer
    product from strand to cooling bed
    collecting area.
     Cooling bed is a steel structure
    divided into two main parts: fixed
    and moving part.
     The billet is transferred step by
    step.
     Product Rotation offer better
    cooling pattern.
     Product is handled through
    overhead crane to billet yard
    storage area.
    11
    Process of Continuous casting
    Secondary
    Primary
    cooling
    Chemical water
    composition Oscillation
    Strand
    Lubrication supporting

    Primary solidification secondary


    Molten steel from Cut to desired
    inside mold solidification in spray
    ladle furnace length
    zone

    Level
    measurement
    Super heat
    Product Product Product
    Storage inspection cooling

    12
    From liquid to cold steel
    Heat Strand Billet

    1-Ladle 6-Cooling to < 500 ◦C


    Liquid steel Cold billet
    Heat

    2-Tundish 5-Cutting
    Liquid steel Solidified
    Heat +Mixed Hot steel-Strand

    3-Mold 4-Spray cooling


    Partial solidified steel To complete solidification
    Heat to strand Strand

    13
    From liquid to cold steel

    14
    Caster breakout
     Serious problem happens in spray
    cooling zone after the strand leaves the
    mold.
     The shell formed inside the mold due to
    any deviation from correct process can
    not support liquid steel inside and liquid
    steel take a path outside cause
    production interruption and damage of
    equipment.
     Possible reasons may be related to steel
    or to process

    15
    Casting Start

    16
    Product Quality
     Main product defects are
    related to billet shape as
    rhomboidity.
     Cracks in product is
    serious problem and may
    be it surface cracks or
    internal cracks
     With productivity it is one
    of Main machine
    performance indicators
    17

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