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Measures to control steel breakout in continuous casting molds and the function of steel breakout prediction

Created on：2024-03-20

01 Necessary measures to control steel leakage
●The temperature is measured only after the pouring platform is blown with argon to ensure temperature uniformity. According to the chemical composition of the steel, the pouring flow temperature must be kept superheated at about 60°C before the ladle can be placed on the turntable to ensure that the molten steel is overheated by 25 to 35°C in the tundish.

●Control the drawing speed based on the temperature monitored in the ladle. The carbon content in the steel is constant to ensure that the temperature increases as the drawing speed decreases, and the drawing speed increases as the temperature decreases. Therefore, the drawing speed must be adjusted correctly according to the temperature and carbon content of the steel. Gradually increase the casting speed and maintain steady-state continuous casting at a certain casting speed. Any interruption in continuous casting will reduce the casting speed.

●Any mold powder has an expiration date, so it should not be used after the expiration date. The mold powder is only opened during casting and placed under a high wattage light bulb to dry. Open bags of mold powder cannot be used when recasting. Select the appropriate mold flux according to the specified chemical composition of the steel. At the beginning of casting, an initial mold flux with low viscosity and low melting point is used. For billet casters, ensure uniform distribution of linseed oil in the crystallizer.

●For slab/bloom continuous casters, measure the thickness of the slag pool to determine whether the thickness of the slag pool exceeds 10mm and the equipment stroke consisting of steel, copper and aluminum wires attached to the steel plate, which helps avoid slag inclusions , the shell is evenly lubricated.

●For high-speed billet continuous casting machines, molds with multiple tapers can be used instead of traditional linear taper molds. Check the crystallizer for deformation (if any). Select the appropriate mold taper and adjust the taper to fit the narrow face based on the steel grade and the way it solidifies on the slab/bloom caster.

●Before the start of continuous casting, check the water flow in the crystallizer by measuring the increase in water pressure to find out the blockage (if any). In general, check for differences in inlet and outlet water temperature, pressure and flow, as well as flow equipment. Water quality should also be checked. Depending on the grade of steel and its solidification method, the mold cooling mode, i.e. water flow rate (1/min), is adjusted to suit various mold surfaces. In order to control the bonding, a thermocouple is used to detect changes in crystallizer wall temperature and the pulling speed is reduced so that the shell continues to grow evenly. For a given caster, ensure that the difference between the inlet and outlet water temperatures does not exceed a specified value during casting.

● Ensure that the maximum radius of the fillet along the copper plate is 0.2mm. If corner joints exist at copper plate joints, they should be filled with plaster or lime before starting casting.

●Install an automatic mold liquid level controller on the continuous casting machine to maintain the steel liquid level in the mold. In order to distinguish the molten steel and slag in the crystallizer and check the slag inclusion, an electromagnetic sensor is installed on the crystallizer.

●Before casting, adjust the tundish nozzle and perform centering. To deal with the blockage of the water outlet of the tundish, before placing the ladle on the rotary table, ensure that the Ca-Si core wire is sprayed in to meet the requirements of high-aluminum steel, so as to form low-melting point calcium aluminate. Use a freezer to prevent the stopper rod from turning.

●By using a protective flux for the tundish metal and using a shielding plate between the ladle and the tundish, ensure appropriate deoxidation products and prevent the generation of secondary oxidation products. For billet continuous casters, Mn/Si>3 must be maintained.

●Use asbestos rope to seal the dummy rod head and use a chill box to ensure the correct distribution of the chill box before casting.

●To determine blockage, if any, check the spray cooling nozzles and water flow.

02 Steel breakage prediction system
The BPS-K600 steel breakout prediction system based on artificial neural network developed by Wuhan Zhongfeiyang. The combination of artificial intelligence and information technology overcomes the shortcomings of traditional logic forecast models and has adaptive, self-organizing and self-learning functions. The BPS series steel breakage prediction system has flexible and complete system configuration, modular structural design, and professional environmental protection measures. Zhongfeiyang provides complete LGK series special tools and accessories for steel breakage prediction, which greatly reduces the use and maintenance cost and maintenance workload of the system.