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2022 Vol. 41 No. 5
Published: 2022-10-18
Continuous Casting Technology
Strand Quality
Technology Exchange
Continuous Casting Technology
1
WU Hai-long, CEN Chuan-fu, CAO Yu, ZHONG Shan, LIU Ying, LU Hao-jian
Numerical simulation of temperature field of continuous casting billet during transporting to direct rolling
The temperature of continuous casting billet is the key to the successful implementation of the continuous casting direct rolling process. In order to solve the problem of the connection between the temperature and speed of the continuous casting billet in the continuous casting direct rolling process, the temperature change of the continuous casting billet and the thickness of the solid shell in the whole process from the meniscus of the mold to the front of the rolling mill were simulated by ANSYS software. On this basis, the influences of the processing parameters, such as the casting speed, casting temperatures and specific water volume on the billet temperature, the thickness of the solid shell and the position of solidification terminal were analyzed. The results showed that under the conditions of the casting speed of 2.8 m/min, casting temperature of 1 550 ℃ and specific water volume of 1.4 L/kg, the average temperature of the billet before reaching the rolling mill can still remain more than 900 ℃, which can meet the requirements of direct rolling process. The research results would be beneficial to the connection between continuous casting and rolling, and provide useful reference for the transformation of continuous casting workshop in steel plants.
2022 Vol. 41 (5): 1-9 [
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10
SUN Ren-bao, MA Jun-peng, WANG Wei, CHEN Fa-tao, LI Xiao-jun
Application of combined electromagnetic stirring in ferritic stainless steel
In the process of continuous casting of ferritic stainless steel, the use of box-type electromagnetic stirring alone has problems such as unstable control of the ratio of equiaxed grains in the macrostructure and white bright bands caused by the stirring intensity. In order to improve the macrostructure of ferritic stainless steel, the application of combined electromagnetic stirring in ferritic stainless steel was carried out. Under the condition of industrial test, the effects of three stirring modes, including single box type, single roller type and box and roller combined type on the equiaxed crystal ratio and macrostructure of the ferritic stainless steels of 410, 430, 441 were analyzed. The results show that neither the single box type nor the single roller type can stably control the equiaxed grain ratio of the ferritic stainless steel. The box-type electromagnetic stirring is applied to the upper section of the second cooling or the roller-type electromagnetic stirring is separately applied to the lower section of the second cooling, and the proportion of equiaxed crystals is below 50%. Adopt box type and roller type combined electromagnetic stirring, under the condition of higher casting speed (CCM1), the parameters of the combined electromagnetic stirring are optimized. The stirring parameter of the box type is 1 210 A、2.7 Hz and the roller type is 350 A、8 Hz, which can stably control the ratio of equiaxed crystals to more than 60%, and at the same time can eliminate the secondary columnar crystals to obtain an ideal macrostructure. Under the condition of lower casting speed (CCM8), combined electromagnetic stirring parameters of the box stirring is 1 200 A、3.5 Hz and roll stirring is 380 A、8 Hz, the white light band defect was significantly improved.
2022 Vol. 41 (5): 10-16 [
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17
MA Ming, ZHENG Xu-tao, YU Yao, WANG Shi, TIAN Zhen, XIE Qing-hua
Simulation of the effect of EMBr on the dynamic behavior of molten steel in thin slab with high casting speed
In the research on the production technology of thin slab with high casting speed, the steel flow field in the mold is the key factor to determine the slab quality problems such as the uniformity of slab shell and the probability of liquid level slag entrapment. EMBr can significantly change the flow field of molten steel, which is the key process technology to improve these problems. Therefore, it is essential to simulate, analyze and optimize the steel flow field in the mold. In the previous research, there are few relevant data and theoretical guidance, and there are few reports on the analysis and research of high casting speed continuous caster for thin slab endless rolling line. Based on the high casting speed continuous caster, the magnetic induction distribution of different electromagnetic braking current intensity in the mold is obtained by numerical simulation. Using the coupling mode of electromagnetic and multiphase flow, the flow field distribution and liquid surface morphology of steel in mold under different magnetic induction intensity are simulated, and the influence of electromagnetic braking on liquid surface fluctuation is analyzed. The results show that: Based on the fixed working condition environment, when the electromagnetic braking current value is 175 A, the flow field of steel is evenly distributed, the liquid surface velocity of steel is relatively lowest, the maximum velocity is about 0.6 m/s, and the liquid surface height difference and shear angle are relatively minimum. This condition is most conducive to reducing the probability of slab defects caused by uneven shell or liquid level slag. When the current value is 225 A, compared with 125 A, the magnetic induction intensity at the liquid level of steel is only increased by 0.02 T, and the time for the liquid level to reach stability is only shortened by about 1 s. Therefore, there is an optimal current value under comprehensive evaluation.
2022 Vol. 41 (5): 17-22 [
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23
ZHAO Zhan-shan, WANG Shi, REN Tao, LI Yi, ZHANG Zhong-fu, WANG Qing
Flow field simulation and optimization of multi-strand tundish
In order to reduce the probability of slag rolling and improve the removal ability of inclusions, the internal structure of multi-strand tundish in a steel plant was optimized by physical simulation and numerical simulation. The results show that the elevation angle of the diversion hole has a great influence on the flow field and temperature field in the tundish. The improved retaining wall uses 25 ° elevation diversion holes to reduce the maximum temperature difference of each flow from 5.2 ℃ to 2.4 ℃. The smaller elevation angle of the diversion hole is beneficial to the removal of inclusions, and the flow uniformity at the elevation angle of 25 ° is better. Increasing the dam height is also conducive to the floating of inclusions. The recommended dam height is 650 mm. In addition, it is recommended to keep the pouring height above 100 mm to eliminate the adverse effect of slag entrapment.
2022 Vol. 41 (5): 23-29 [
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30
ZHAO Ze-kun, LI Su-qin, GUO Peng-hui
Photocatalytic removal of Cr(Ⅵ) from α-Fe
2
O
3
nanoparticles prepared by continuous casting iron sludge
Continuous cast iron mud is rich in iron, so resource utilization is an inevitable choice. In this paper, we successfully prepared α-Fe
2
O
3
nanoparticles from continuous casting iron sludge by hydrothermal method and realized high value-added utilization. The prepared α-Fe
2
O
3
nanoparticles were polymerized into uniform spherical mesoporous structure with a specific surface area of 48.78 m
2
/g and the average grain size was about 40-50 nm. Large specific surface area and small grain size provided a large number of photocatalytic active sites, which was conducive to improving the photocatalytic performance of the material. Therefore, the α-Fe
2
O
3
nanoparticles has a good removal rate of Cr(Ⅵ) polluted wastewater, and the removal rate can reach 100% within 180 min. In addition, after 5 cycles, the removal efficiency of Cr(Ⅵ) can still reach 89.2%, indicating that α-Fe
2
O
3
nanoparticles has good reusability. The mechanism of photocatalytic removal of Cr(Ⅵ) was studied. Photogenerated electron (e
-
), hydroxyl radical (·OH) and superoxide anion (·O
2
-
) are the main active substances involved in the removal of Cr(Ⅵ). Therefore, this study can transform the industrial by-product of continuous cast iron sludge into high value-added nanomaterials, and provides a new idea for the removal of heavy metal wastewater, which has high practical application value.
2022 Vol. 41 (5): 30-36 [
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88
LIU Xi-mao
Effect of flow control device on steel cleanliness in four-flow tundish
In order to study the influence of flow control device on the water cleanliness of steel tundish, the method of numerical simulation and industrial test verification was used to optimize the billet continuous casting tundish. The response time was increased by 5 s and the peak time was increased by 371 s by adding a U-shaped retaining wall to the prototype tundie, which improved the short-circuit flow phenomenon of molten steel in the tundie,and the average residence time increases by 53 s, the dead zone volume fraction decreases by 4.1%, and the piston zone volume fraction increases by 17.3%, which improves the floating condition of inclusions. The consistency level of each flow is also improved.The results of industrial tests show that the inclusion removal rate of molten steel in the tundie increases by 29.05% when the U-shaped retaining wall is added between the receiving zone and the pouring zone, the maximum size of inclusion in each zone of the tundie decreases by 26 μm, the inclusion removal rate on the billet increases by 38.42%, and the maximum size of inclusion on the billet decreases to less than 16 μm. The use of U-shaped retaining wall in tundish improves the cleanliness of molten steel and the quality of billet.
2022 Vol. 41 (5): 88-94 [
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95
XING Li-yong, GAO Yu, ZHANG Cai-dong, YAO Hong-yong, LI Jie, TIAN Zhi-qiang
Numerical simulation of structure optimization of one-strand slab tundish dam
Based on the one-strand slab tundish of a steel corporation, the numerical simulation method was used to study the molten steel flow field and the removal of inclusions before and after the optimization of the tundish dam structure. The result shows that the optimized dam allows part of molten steel to flow out through the diversion hole, which reduces the impact of molten steel flowing upward along the dam on the liquid surface, and also avoids short-circuit flow formed by the direct outflow along the bottom. The average residence time of 30° diversion hole in the tundish is the longest, the dead zone is the smallest, and flow state is the most reasonable. When the angle of diversion hole is further increased, the molten steel flows out of the diversion hole and quickly merges into the large circulation behind the dam, and the residence time decreases. The inclusion removal rate of the 30° diversion hole is about 11% higher than that of the original structure. When the angle is further increased, the removal rate of inclusions decreases, but it is slightly better than the original dam structure. After the industrial application of the new dam structure, the results of inclusion ratings have improved significantly.
2022 Vol. 41 (5): 95-100 [
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Strand Quality
37
ZHENG Xiang, QI Jie, ZHENG Yi-hao, LIU Cheng-jun
Dissolution behavior of CeAlO
3
inclusion in the tundish flux
The existence of large amounts of rare earth inclusions with high melting points in steel can cause clogging of submerged entry nozzles during continuous casting. Dissolution mechanism of CeAlO
3
inclusion in the tundish flux was investigated by static method and SHTT in-situ observation. Results of static experimental showed that an intermediate layer formed during the dissolution process of CeAlO
3
. With the increase of dissolution time, the dissolution of CeAlO
3
became more serious, and the size of the CaCeAl
3
O
7
formed in interfacial layer increased gradually. SHTT in-situ observation experimental showed that the apparent size of CeAlO
3
particle first decreased, then increased and finally remained relatively stable during the dissolution process. The CeAlO
3
reacted with CaO in the slag to form a product layer in the current slag, and then the formed product layer was dissolved into the slag. Therefore, the dissolution method of CeAlO
3
was indirect dissolution in the current slag.
2022 Vol. 41 (5): 37-42 [
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43
LIU Wei, WU Hua-jie, LI xue, SUN Yan-hui, LI Ming
Effect of refining slag composition on cleanliness of 42CrMo steel
In order to study the effect of different refining slag on the cleanliness and the number and size of inclusions in 42CrMo steel,the influence of a quaternary slag system of CaO-Al
2
O
3
-SiO
2
-MgO on cleanliness and inclusion control in 42CrMo steel was investigated using a slag-steel equilibrium test and FactSage thermodynamics in this research. When the initial slag basicity (the mass ratio of CaO/SiO
2
) and the calcium to aluminum ratio (the mass ratio of CaO/Al
2
O
3
) are 5 and 1.8, respectively, the T.[O] content in the steel can be reduced to 7.5×10
-6
,at the same time, the inclusion size is well controlled, and it is less than 8 μm, according to the findings. The refining effect of 42CrMo steel is the best under this slag system condition. The study also showed that the inclusion composition in the steel was greatly affected by the slag system, especially the Al
2
O
3
content of the inclusions in the steel was greatly affected by the activity of Al
2
O
3
in the slag, the refining slag system with high Al
2
O
3
activity has a weak ability to remove inclusions Al
2
O
3
, resulting in a high content of inclusions Al
2
O
3
in the steel under this refining slag system.
2022 Vol. 41 (5): 43-49 [
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50
ZHAO Xin-kai, TIAN Feng-xi, GAO Wen-juan, ZHANG Ying-tao, MAO Fu-lai, ZHANG Jiong-ming
Behavior analysis of non-metallic inclusion groups in bearing steel during bloom casting
In order to study the aggregation of non-metallic inclusions in the continuous casting process of bearing steel, a flow-solidify-coupled model of solidification process was established. The migration behavior of inclusions in the casting process was studied by means of numerical simulation combined with factory tests. The results show that, as the comparison of casting varieties, such as mould sections, the M-EMS, and SEN types, the parameters of bigger sections, stronger M-EMS stirring and many-side-port SEN nozzles, are more favorable to improve the inclusions below 10 μm in the bloom, and the inclusions of 5-10 μm level are most easily captured by the raw casting shell. Results also show that, high number density of microscopic inclusion groups in tundish, which are below 5 μm, will promote the collision and migration during the pouring process, resulting in an accumulation of inclusion groups with 20-30 μm in the bloom, but has little effect on large size inclusion groups, which are above 50 μm. The inclusion groups with that macro size level in the bloom are mainly originated from tundish directly. These results are of great significance to clarify the origin of inclusions and improve the fatigue life of bearing steel.
2022 Vol. 41 (5): 50-61 [
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62
LIU Tao, CHEN Yong-feng, WANG Dong-xing, ZHAO Li, ZHANG Ya-bing, ZUO Xiao-tan
Control of surface cracks in boron containing steel billet
The surface cracks of boron containing steel billet were observed by scanning electron microscope and metallographic analysis. Combined with the mechanism of cracks formation, the surface cracks of Wuhu Xinxing 10B21 boron containing steel billet were analyzed from three aspects: mold copper pipe, secondary cooling zone cooling and physical and chemical properties of mold slag. The results show that optimizing the material and taper of mold copper tube, adjusting the specific water content and distribution ratio in the secondary cooling zone and coordinating the lubrication and heat transfer effect of mold flux are conducive to reduce the surface crack defects of boron containing steel billets. The conducted production practices were as following. The total taper was reduced from 2.0%/m to 1.8%/m by changing the common hard Cr plating to Ni-Cr composite plating. The specific water volume in the secondary cooling zone was reduced from 0.6 L/kg to 0.5 L/kg, and the distribution ratio was adjusted from 34∶34∶20∶10∶2 to 31∶26∶20∶13∶10. The viscosity of mold flux decreased from 1.358 Pa·s to 1.169 Pa·s, and the alkalinity increased from 0.75 to 0.98. By applying the above measures, the surface crack rate of the final slab is reduced from 17.4% to 2.3%, the billet surfaces were smooth, the vibration marks were flat and regular, and the yield of rolled products was also increased from 86% to 95%.
2022 Vol. 41 (5): 62-68 [
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69
JIAO Kui-ming, ZHANG Ya-bing, ZHAO Li, ZUO Xiao-tan, WANG Dong-xing, CHEN Yong-feng
Cleanliness analysis of the whole process of 10B21 microalloyed steel production process
In order to explore the factors affecting the production stability of 10B21 steel, improve the quality of steel and meet the needs of customers, the inclusions of clean steel in the whole process were sampled and analyzed. The results show that there are mainly seven types of inclusions in each station of the whole process, namely CaO-Al
2
O
3
-MgO-CaS-TiN, CaO-Al
2
O
3
-MgO-CaS, Al
2
O
3
, MnS, MnS-Al
2
O
3
, Al
2
O
3
-TiN and MnS-TiN. Except that the type of sample inclusions in converter station is relatively complex, the inclusions in other stations are mainly CaS-Al
2
O
3
-MgO-CaO-TiN. The oxygen and nitrogen content fluctuates greatly in different furnace times, especially the control of the oxygen content at the end of the converter is unstable, the inclusions change greatly in the LF refining process, and the size generated after soft blowing operation is 80-100 μm, the main component of which is CaO-Al
2
O
3
-MgO-CaS-TiN. That is, with calcium oxide and alumina as the nucleation center, magnesium oxide is accompanied outside and wrapped by calcium sulfide and titanium nitride. The inclusions of this component begin to form after LF refining calcium feeding line. Due to the low fluidity of refining slag, poor coverage effect on liquid steel, secondary oxidation is easy to occur, resulting in the obvious aggregation and growth of inclusions in the soft blowing stage.
2022 Vol. 41 (5): 69-75 [
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76
QIAN Zhi-you, WANG De-fu, DENG Jun-zong, GUO Rui, ZHANG Xiao-di
Control measures for dented cracks at corners of thick slabs
Corner dent cracks are a common quality defect in the production of thick slab continuous casting. With the increase of slab thickness, the incidence of corner dent cracks continues to increase, which has become an important factor restricting the quality improvement and variety development of thick slabs. For slabs with 260 mm×2 800 mm and 320 mm×2 800 mm sections, the position, morphology and structure of the depression cracks in the corners were studied, the influencing factors of the solidification and shrinkage behavior of the slab corners in the mold were analyzed, and the control method of corner depression crack was obtained.Through the development of curved narrow surface copper plate mold, adapt to the billet shell shrinkage in the mold. The cooling time of secondary cooling zone is prolonged by increasing the logarithm of narrow edge foot roll. The crystallization temperature and heat transfer performance can be increased by increasing the viscosity of the slag. Control measures such as adjusting mold vibration parameters effectively solve the problem of corner sag crack in thick slab, and the incidence of dented cracks at the corners of 260 mm×2 800 mm and 320 mm×2 800 mm was reduced to 0.41% and 0.86%, which creates favorable conditions for hot loading and hot sending of slab.
2022 Vol. 41 (5): 76-81 [
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82
WANG Long-fei
Study and control of surface star cracks on Q355B steel plates
In order to eliminate the surface star cracks of hot rolled Q355B steel plates, a series of methods including thermodynamic calculation, metallographic examination, grinding, shot blasting, acid pickling, macroscopic evaluation, SEM and EDS analysis were conducted to probe into the reasons. The results showed there is no finding of decarburized layer, oxidation origin, the secondary phase particle, inclusion and copper in the cracks, which indicated the occurrence of surface star cracks is not from slab defect. The low cracking ratio of steel plate produced by cold charging and analysis of two-phase domain demonstrated the occurrence of surface star cracks is mainly caused by hot charging of slabs in the two-phase domain between 767 ℃ and 677 ℃. Through independent design and application of spraying device, and meanwhile controlling the temperature more than 790 ℃ before entering spraying zone and then less than 510 ℃ when leaving spraying zone, the slab surface temperature before entering the heating furnace was decreased to be less than 635 ℃. Eventually, the star crack ratio decreased from 0.99% before technology improvement to 0.07% at 2021.
2022 Vol. 41 (5): 82-87 [
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Technology Exchange
101
LI Wei, HUANG Da-jun, WU Shuai, XIA Jin-kui, LIN Qian, ZHANG Li-qiang
Continuous casting billet online fixed weight cutting technology process practice
Aiming at the problems of low pass rate of constant temperature and constant tension in the production process of ESteel and the existence of molten steel and the weight difference between the flow of the casting machine and the rhythm of the furnace, the dynamic model calculation of the continuous casting billet online is introduced to monitor the continuous casting process status and the quality of the casting billet in real time. This model cooperates with the precision upgrade of casting machine and rolling mill equipment, stabilizes the negative difference rate of rolled products, and reduces the tensile speed frequency for casting machines with a pulling speed ratio greater than 90%. The results show that the on-line weighing rate of continuous casting blank is controlled to be greater than 80% within ±4 kg, the output of non-ruler materials within 4 m is greatly reduced, and the rolling scale rate is increased to more than 99.4%.
2022 Vol. 41 (5): 101-107 [
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108
SUI Zhi-song, KANG Xin-lei, HAN De-fei, LIAO Zheng-fa, ZHANG Chao-jie, ZHANG Li-qiang
Practice on quality improvement of 220 square low carbon alloy steel billet
In order to study the influence of out of squareness and surface cracks on the quality of the slab, this paper adopts the methods of improving the matching of mold flux and steel grades, adjusting the distance between the water gaps of the mold and optimizing the secondary cooling process through theory and production practice. The effects of different Big R angle copper pipes on surface cracks were compared, and the mold was optimized to suppress cast-off and surface cracks. The results show that in the practice of optimizing the surface quality of 220 square billets with large R-angle copper tubes, rationally controlling the cause of out of squareness and effectively controlling the surface cracks of the billet can stably improve the quality of the billet.
2022 Vol. 41 (5): 108-113 [
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114
HAN Lei-lei, ZOU Chun-feng
Discussion on defect types and mechanism of ring forgings forged from round billets
In order to reveal the causes of unqualified inspection of large round forgings, the forms and composition of various types of defects are discussed, the macroscopic and microscopic characteristics of each type of defects are analyzed,and the causes of the defects and the solutions are proposed. There are three forms of slag inclusion, internal crack and stress that they cause unqualified inspection of large round forging, and the main technological measures to prevent the failure of flaw detection are preventions of secondary oxidation slag,mould fluxes and nozzle blocking to ensure uniform cooling in the cooling process of continuous casting, at the same time reduce the oxygen content in the steel, and avoid the processing method of stress concentration etc.
2022 Vol. 41 (5): 114-119 [
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120
HAN Bao, DENG Yong, YANG Li-bin, WANG Long-xing
Research and application of fluorine-free environment friendly KR desulfurizer
Fluorine-free environmental protection desulfurizer is significance for the protection of environmental and fluorine resources. Through the calculation and analysis of the desulfurization mechanism of molten iron, it is concluded that using Al
2
O
3
micro powder instead of fluorite as flux for KR molten iron desulfurization can promote the flux, reduce the oxygen activity of molten iron and increase the reaction temperature.Through melting point and process research, the optimum ratio of fluoride-free desulfurizer is 15∶85.The experimental results showed that adding a certain amount of Al
2
O
3
into the desulfurizer is beneficial to accelerate the speed of desulfurization reaction, reduce the melting point of lime, increase the desulfurization rate of desulfurizer, and improve the utilization rate of lime particles. The average consumption of free-fluorine desulfurizer is decreased more than 0.3 kg/t, the average sulfur content was 0.003 1%, and the average desulfurization rate was 86.13%. It can meet the demand of hot metal desulfurization task and realize the complete replacement of fluorine desulfurizer.
2022 Vol. 41 (5): 120-124 [
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125
AN Shou-yong, WANG Peng-fei
Application of VUHZ detection and control system in ESP Line
The detection and control of molten steel level in mold is one of the core links of continuous casting machine production control. Stable liquid level in mold is of great significance to improve the internal and surface quality of casting slab, avoid the involvement of slag and other non-metallic inclusions, and reduce production accidents such as breakout or steel overflow. Especially for ESP thin slab caster with high cast speed and high throughput, it requires higher accuracy of liquid level detection and control. All mold level sensors used in ESP continuous casting machines are NKK systems, which have mature application experience. Aiming at the first application of VUHZ level detection system in ESP caster, the problems affecting VUHZ level detection were solved by optimizing system control parameters, signal compensation and cooling water system. The practice shows that the level control accuracy and level fluctuation of VUHZ system can meet the requirements of field process production under the condition of high pulling speed.
2022 Vol. 41 (5): 125-131 [
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