Abnormalities in Continuous Casting

Abnormalities in Continuous Casting
A project report by:
Rupam Mandal 2920

Diptesh Sanfui 2921
Swarnendu Hazra 2922
Saurabh Das 2923
Kaustav Dey 2924
Suvankar Pal 2925 Metallurgy and Materials Engineering
Deshik Sarkar 2926 Bengal Engineering and Science University,

Shibpur
Acknowledgements
We would like to take this opportunity to express our gratitude to Mr. P. K. Sen (DGM,QA&TD) and Mr.
G.Rajaraman (AGM, QA&TD) without whose guidance this project would not have been materialised.
We would also like to express our heartfelt appreciation to Mr. Y Lokeshwar Rao who have been with us at
every step of this project. He has helped us to understand each and every aspect of this project in a far better way.
We would also like to thank Mr. Sarthak Majumdar (QA&TD) who helped us a lot by providing necessary
mathematical data and deep inside about the practical aspects for properly analysing them to successfully complete
this project.
We are grateful to Mr. Santanu Chakrabarty , who helped us a lot in many different ways since the beginning
for successfully completing the project.
And last but not the list loads of THANKS to all those kind and generous people who gave us lift to the
plant.
Abnormalities in Continuous Casting | 1

-INDEX-
Contents Page No.
Lay out of Visakhapatnam Steel Plant ------------------------------------- 4
An Overview of VSP ------------------------------------- 5
Background ------------------------------------- 5
VSP technology: the state - of - the art ------------------------------------- 6
Major Sources of Raw Material ------------------------------------- 6
Water Supply ------------------------------------- 7
Power Supply ------------------------------------- 7
Major Departments ------------------------------------- 7
Raw Material Handling Plant(RHMP) ------------------------------------- 7

Coke Oven and Coal Chemical Plant(CO&CCP) ------------------------------------- 7
Sinter Plant(SP) ------------------------------------- 8
Blast Furnace(BF) ------------------------------------- 8
Steel Melting Shop(SMS) ------------------------------------- 8
Continuous Casting Department(CCD) ------------------------------------- 9
Rolling Mills(RM) ------------------------------------- 9
Light and Medium Merchant Mill(LMMM) ------------------------------------- 10
Medium Merchant and Structural Mill(MMSM) ------------------------------------- 10
Wire Rod Mill(WRM) ------------------------------------- 10
Introduction ------------------------------------- 12
General Overview of Steel Melt Shop ------------------------------------- 12
Description Of the Facilities ------------------------------------- 13
Mixer Shop ------------------------------------- 13

Bulk Material Handling Section(BMHS) ------------------------------------- 14
Converter Bay ------------------------------------- 14
Characteristics of Oxygen Lance ------------------------------------- 15
Scrap Yard ------------------------------------- 15
Slag Yard ------------------------------------- 15
Ladle preparation Bay ------------------------------------- 16
Argon Rinsing Station(ARS) ------------------------------------- 16
Tundish Preparation Bay ------------------------------------- 16
Continuous Casting Machine ------------------------------------- 17
Facilities and Equipment-Lift and Turn stand ------------------------------------- 17

Mould Oscillating System ------------------------------------- 17
Copper Mould ------------------------------------- 17
Strand Cooling ------------------------------------- 17
Dummy Bar ------------------------------------- 18
Backup Rollers Sections N1 and N2 ------------------------------------- 18
Withdrawal And Strengthening Rollers ------------------------------------- 18
Technical Details of CC machine ------------------------------------- 18

Gas Cutting Machine(GCM) ------------------------------------- 18
Bloom Storage Yard ------------------------------------- 18
Principles of Continuous Casting Process ------------------------------------- 19
The Continuous Casting Machine ------------------------------------- 20
Different Types of Machine ------------------------------------- 21
General Features of Continuous Casting Machine at VSP------------------------------------- 23
Casting Powder ------------------------------------- 25
Abnormalities in Continuous Casting Section ------------------------------------- 26
Running Tendency ------------------------------------- 26

Breakout ------------------------------------- 28
Choking/ Clogging ------------------------------------- 37
Observation Tables for the Past Few years ------------------------------------- 45
Few Case Studies ------------------------------------- 55

AN OVERVIEW OF VSP
Visakhapatnam Steel Plant, the first coastal based Steel Plant of India is located, 16 KM South West of city
of Destiny i.e. Visakhapatnam. Bestowed with modern technologies, VSP has a installed capacity of 3 Million
Tonnes per annum of Liquid Steel and 2.656 Million tonnes of saleable steel. At VSP there is emphasis on total
automation, seamless integration and efficient upgradation, which result in wide range of long and structural products
to meet stringent demands of discerning customers within India and abroad. VSP products meet exalting International
Quality Standards such as JIS, DIN, BIS, BS etc.
VSP has become the first integrated Steel Plant in the country to be certified to all the three international
standards for quality (ISO-9001), for Environment Management (ISO-14001) & for Occupational Health & Safety
(OHSAS-18001) The certificate covers quality systems of all operational, maintenance, service units besides
Purchase systems, Training and Marketing functions spreading over 4 Regional Marketing Offices, 20 branch offices
and 22 stock yards located all over the country. VSP by successfully installing & operating efficiently Rs. 460 crores
worth of Pollution Control and Environment Control Equipment and converting the barren landscape by planting
more than 3 million plants has made the Steel Plant, Steel Township and surrounding areas into a heaven of lush
greenery. This has made Steel Township a greener, cleaner and cooler place, which can boast of 3 to 40 C lesser
temperature even in the peak summer compared to Visakhapatnam City. SP exports Quality Pig Iron & Steel
products to Sri Lanka, Myanmar, Nepal, Middle East, USA & South east Asia (Pig iron). RINL-VSP was awarded
"Star Trading House" status during 1997-2000. Having established a fairly dependable export market, VSP plans to
make a continuous presence in the export market. Having a total manpower of about 16,613 VSP has envisaged a
labour productivity of 265 Tonnes per man year of Liquid Steel which is the best in the country and comparable with
the international levels.
BACK GROUND
With a view to give impetus to Industrial growth and to meet the inspirations of the people from South India,
Government of India decided to establish Integrated Steel Plants in Public Sector at Visakhapatnam (AP) and Hospet
(Karnataka) besides a special Steel Plant at Salem (Tamil Nadu). The announcement was made in the Parliament on
17th April' 1970 by the then Prime Minister of India late Smt. Indira Gandhi. A site was selected near Balacheruvu
creak near Visakhapatnam city by a Committee set up for the purpose, keeping in view the topographical features,
greater availability of land and proximity to a future port. The foundation stone for the plant was laid by Smt. Gandhi
on 20.01.1971. Seeds were thus sown for the construction of a modern & sophisticated Steel Plant having annual
capacity of 3.4 Million Tonnes of hot metal. An agreement was signed between Governments of India and the
erstwhile USSR on June 12th, 1979 for setting up of an Integrated Steel Plant to produce structural & long products
on the basis of detailed Project report prepared by Dr. M.N. Dustur & Company. A Comprehensive revised DPR
jointly revised by Soviets & Dr. Dastur & Company was submitted in Nov' 1980 to Govt. Of India.
The construction of the Plant started on 1st February 1982. Government of India on 18th Feb'82 formed a
new Company called Rashtriya lspat Nigam Ltd. (RINL) and transferred the responsibility of constructing,
commissioning & operating the Plant
at Visakhapatnam from Steel Authority
of India Ltd. to RINL. Due to poor
resource availability, the construction
could not keep pace with the plans
which lead to appreciable revision of
the plant cost. In view of the critical
fund situation and need to check
further increase in the plant costs, a
rationalized concept was approved
which was to cost Rs. 6849 crores
based on 4th Quarter of 1988. The
rationalized concept was based on
obtaining the maximum output from
the equipment already installed,
planned / ordered for procurement and
achieving higher levels of operational
efficiency and labour productivity.
Thus the plant capacity was limited to 3.0 Million tonnes of Liquid Steel per annum. In the process one of the Steel
Melt Shops and one of the mills were curtailed. The availability of resources were continued to be lower than what
was planned and this further delayed the completion of the construction of the plant. Finally all the units were
constructed and commissioned by July' 92 at a cost of Rs. 8529 crores. The plant was dedicated to nation by the then
prime Minister of India Late Sri P.V. Narasimha Rao. Since Commissioning VSP has already crossed many mile
stones in the fields of production, productivity & exports. Coke rate of the order of 509 Kg/Ton of Hot metal,
average convertor life of 2864 heats an average of 23.6 heats per sequence in continuous Bloom Caster. Specific
energy consumption of 6.07 G Cal/ton of liquid steel, a specific refractory consumption of 8.94kg and a labour
productivity of 265 Ton/man year are some of the peaks achieved (during the year 2004-05) in pursuit of excellence.
VSP Technology : State-of-the-Art
7 meter tall Coke Oven Batteries with coke dry quenching

Biggest Blast Furnaces in the Country
Bell-less top charging system in Blast Furnace
100% slag granulation at the BF Cast House
Supressed combustion-LD gas recovery system
100% continuous casting of liquid steel.
"Tempcore" and "Stelmor" cooling process in LMMM & WRM respectively
Extensive waste heat recovery systems
Comprehensive pollution control measures
Major Sources of Raw Materials
Raw Material Source

Iron Ore Lumps & Fines Bailadilla, MP
BF Lime Stone Jaggayyapeta, AP
SMS Lime Stone UAE
BF Dolomite Madharam, AP
SMS Dolomite Madharam, AP
Manganese Ore Chipurupalli, AP
Boiler Coal Talcher, Orissa
Coking Coal Australia
Medium Coking Coal (MCC) Gidi/Swang/Rajarappa/Kargali

Water Supply
Operational water requirement of 36 mgd is being met from the yeleru Water supply Scheme.
Power Supply
Operation power requirement of 180 to 200 MW is being met through Captive Power Plant. The capacity of
the power plant is 286.5 MW. VSP is exporting 60 MW power to APSEB.
MAJOR DEPARTMENTS:-
Raw Material Handling Plant (RMHP)
VSP annually requires quality raw materials

viz. Iron Ore, fluxes (Lime stone, Dolomite), coking
and non coking coals etc. to the tune of 12-13 Million
tonnes for producing 3 Million Tonnes of Liquid Steel.
To handle such a large volume of incoming raw
materials received from different sources and to ensure
timely supply of consistent quality of feed materials to
different VSP consumers, Raw Material Handling
Plant serves a vital function. This unit is provided with
elaborate unloading, blending, stacking & reclaiming
facilities viz. Wagon Tipplers, Ground & Track
Hoppers, Stock yards Crushing plants, Vibrating
screens, Single/ twin boom stickers, wheel on boom
and Blender recliners. In VSP peripheral unloading has
been adopted for the first time in the country.
Coke ovens & Coal Chemical Plant (Co&CCP)
Blast Furnaces, the mother units of any Steel plant require huge quantities of strong, hard and porous solid
fuel in the form of hard metallurgical coke for supplying necessary heat for carrying out the reduction and refining
reactions besides acting as a reducing agent. Coke is manufactured by heating of crushed coking coal (below 3 mm)
in absence of air at temperature of 1000oC and above for about 16 to 18 hours. A Coke Oven comprise of two hollow
chambers namely coal chamber and Heating Chamber. In the heating chamber a gaseous fuel such as Blast Furnace
Gas, Coke Oven Gas etc. is burnt. The heat so generated is conducted through the common wall to heat & carbonize
the Coking Coal placed in the adjacent coal chamber. Number of ovens built in series one after the other form a Coke
Oven Battery.
At VSP there are three Coke Oven Batteries, 7 Metre tall and having 67 Ovens each. Each oven is having a
volume of 41.6 cu. metre & can hold up to 31.6
Tonnes of dry coal charge. The Carbonization
takes place at 1000 - 10500 C in absence of air
for 16-18 hours. Red Hot Coke is pushed out of
the oven and sent to Coke Dry Cooling Plants for
cooling to avoid its combustion. There are 3
Coke Dry Cooling Plants (CDCP) each having 4
cooling chambers. The capacity of each cooling
chamber is 50-52 TPH.
Nitrogen gas is used as the Cooling
medium. The heat recovery from nitrogen is
done by generating steam and expanding in two
back pressure turbines to produce 7.5 power
each. The Coal chemicals such as Benzoyl (& its
products), Tar (& its products), Ammonium
Sulphate etc. are extracted in Coal Chemical
Plant from C.O. Gas. After recovering the Coal chemicals the gas is used as a by-product fuel by mixing it with gases
such as BF Gas, LD Gas etc. A mechanical, biological & Chemical treatment plant takes care of the effluents.
Sinter Plant (SP)
Sinter is a hard & porous ferrous material obtained by agglomeration of Iron Ore fines, Coke breeze, Lime
Stone fines, Metallurgical wastes viz. Flue dust, mill scale, LD slag etc. Sinter is a better feed material to Blast
Furnace in comparison to Iron Ore lumps and its
usage in Blast furnaces help in increasing
productivity, decreasing the coke rate &
improving the quality of Hot Metal produced.
Sintering is done in 2 nos. Of 312 Sq. Metre,
Sinter Machines of Dwight Lloyd type by
heating the prepared feed on a
continuous metallic belt made of pallets at 1200-
13000 C.
Hot Sinter discharged from Sintering

machine is crushed to +5 mm - 50 mm size and
cooled before despatching to Blast Furnaces.
Parameters of Sintering Machines are
Effective area : 312 Sq. metre
Sintering area : 276 Sq. metre
Sinter bed height : 300 mm
Capacity : 450 T P H each
No. Of wind boxes : 26
The dust laden air from the machines are cleaned in scrubbers & electrostatic precipitators to reduce the dust content
to 100 mg/ m3 level before allowing to escape into the atmosphere and thus helping in maintaining a clean & dust
free environment.
Blast Furnaces (BF)
Hot Metal is produced in Blast

Furnaces, which are tall vertical furnaces. The
furnace is named as Blast Furnace as it is run
with blast at high pressure & temperature. Raw
Materials such as sinter/ Iron Ore Lumps,
Fluxes (Limestone/Dolomite) and Coke are
charged from the top and hot blast at 11000 C -
13000C- and 5.75 KSCG pressure is blown
almost from the bottom. The furnaces are
designed for 80% Sinter in the burden. VSP has
two 3200 cu. metre Blast Furnaces (largest in
India) equipped with Paulworth Bell less top
equipment with conveyor charging. Rightly named as "Godavari" & "Krishna" after the two rivers of AP, the
furnaces will help VSP in bringing prosperity to the state of Andhra Pradesh.Provision exists for granulation of
100% liquid slag at blast furnace cast house and utilization of blast furnace gas top pressure (1.5-2.0 atmospheric
pressure) to generate 12 MW of power in each furnace by employing gas expansion turbines. The two furnaces with
their novel circular cast house and four tap holes each are capable of producing 9720 tonnes of Hot Metal daily or
3.4 Million Tonnes of low sulphur Hot Metal annually.
Steel Melting Shop (SMS)
Steel is an alloy of Iron with carbon up to 1.8%. Hot Metal produced in Blast Furnaces contains impurities
such as Carbon(3.5-4.25%) Silicon (0.4 - 0.5%), Manganese (0.3-0.4%), Sulphur (0.04% max) and Phosphorous
(0.14% max) is not suitable as a common Engineering Material. To improve the quality the impurities are to be
eliminated or decreased by oxidation process. VSP produces steel employing three numbers of top blown Oxygen
Convertors called LD Convertors (L & D stand for Linz & Donawitz - two towns in Austria where this process was
first adopted) or Basic Oxygen Furnaces/Convertors. Each convertor is having 133 cu. Metre volume capable of

producing 3 Million Tonnes of Liquid Steel annually.
Besides Hot Metal, Steel Scrap, Fluxes such as
calcined lime or Dolomite form part of the charge to
the Convertors. 99.5 % pure Oxygen at 15-16 KSCG
pressure is blown in the Convertor through oxygen
lance having convergent Divergent copper nozzles at
the blowing end. Oxygen oxidises the impurities
present in the Hot metal, which are fixed as slag with
basic fluxes such as lime. During the process heat is
generated by exothermic reactions of oxidation of
metalloids viz Si, Mn., P and Carbon and temperature
rises to 17000 C enabling refining & slag formation.
Different grades of steel of Superior quality
can be made by this process by controlling the Oxygen
blow or addition of various ferro alloys or special
additives such as FeSi, FeMn, Si- Mn, Coke Breeze, Aluminium etc. in required quantities while liquid steel is being
tapped from the convertor into a steel ladle. Convertor/LD Gas produced as by product is used as a secondary fuel.
Characteristics of VSP Convertors :
Capacity - 150 Tones per heat/blow

Volume - 133 Cu. Metre
Convertor Sp. Volume - 0.886 Metre Cube per tonne
Tap to Tap Time - 45 mts - 60 mts
Height to Diameter ratio - 1.36
Lining i) Working - Tar Dolomite Bricks
ii) Permanent - Crome Magnesite Bricks
Av. Lining Life - 2445 heats (2004)
Liquid Steel produced in LD Convertors is solidified in the form of blooms in continuous Bloom Casters.
However, to homogenise the steel and to raise its temperature, if needed, steel is first routed through, Argon rinsing
station, IRUT (Injection Refining & Up temperature) / Ladle Furnaces.
Continuous casting Department (CCD)
Continuous casting may be defined as teaming of liquid steel in a mould with a false bottom through which
partially solidified ingot/bar (Similar to the shape & cross section of the mould) is continuously withdrawn at the
same rate at which liquid steel is teamed in the mould.
Facilities at a continuous casting machine include a lift and Turn table for ladles, Copper mould, oscillating
system tundish, Primary & Secondary Cooling arrangement to cool the steel bloom. Gas cutting machines for cutting
the blooms in required lengths (Av. 6 metres long)
At VSP we have six-4 strand continuous casting machines capable of producing 2.82 Million Tonnes/year
Blooms of size 250 x 250 mm and 250 x 320 mm. Entire quantity of molten steel produced (100%) is continuously
cast in radial bloom casters which help in energy conservation as well as production of superior quality products.
Rolling Mills
Blooms produced in SMS-CCD do not find

much applications as such and are required to be
shaped into products such as Billets, rounds, squares,
angles (equal & unequal), Channels, I-PE Beams, HE
Beams, Wire rods and reinforcements bars by rolling
them in, three sophisticated high capacity, high speed,
fully automated rolling mills, namely Light & Medium
Merchant Mills (LMMM), Wire Rod Mill (WRM) and
Medium Merchant and Structural Mill (MMSM).

Light & Medium Merchant Mill (LMMM)
LMMM comprises of two units. In the Billet/Break down mill 250 x 320 mm size blooms are rolled into
Billets of 125 x 125 mm size after heating them in two nos. of Walking beam Furnaces of 200 Tons/hr capacity each.
This unit comprises of 7 stands (2 horizontal 850 x 1200 mm) and 5 alternating vertical & horizontal stands (730 x
1000 mm & 630 x 1000 mm) Billets are supplied from this mill to Bar Mill of LMMM & Wire Rod Mill. The billets
for rolling in bar mill of LMMM are first heated in 2 strand roller hearth furnace of 200 T/h capacity to temperature
of 11500 C-12000 C. The bar mill comprises of 26 stands 8 stand double stand roughing train, 2 nos. of 5 stands,
double strand Intermedial train & two nos. 4 stand single strand finishing trains. The mill is facilitated with temp
core heat treatment technology evaporative cooling system in walking beam furnaces, automated pilling & bundling
facilities, high degree of automation and computerization. The mill is designed to produce 710,000 tons per annum of
various finished products such as rounds, re-bars, squares, flats, angles, channels besides billets for sale.
Medium Merchant & Structural Mill (MMSM)
This mill is a high capacity continuous mill consisting of 20 stands arranged in 3 trains.
Roughing train having a 8 stands (4 two high horizontal stands, 2 vertical stands and 2 combination stands)
-Intermediate Train has 6 mill
stands as per details given below.
2 high horizontal stands
2 combination stands
2 horizontal stands / two universal
stands
Finishing Train - consists of 6
stands namely
2 combination stands
4 horizontal stands / 4 universal
stands
The feed material to the mill is 250
x 250 mm size blooms, which is heated to
rolling temperatures of 1200 0C in two
walking beam furnaces. The mill is
designed to produce 8,50,000 tons per
annum of various products such as rounds,
squares, flats, angles (equal & unequal), T bars, channels, IPE beams / HE beams (Universal beams).
Wire Rod Mill (WRM)
Wire Rod Mill is a 4 strand, 25 stands fully automated & sophisticated mill. The mill has a four zone
combination type reheating furnace
(walking beam cum walking hearth)
of 200TPH capacity for heating the
billets received from billet mill of
LMMM to rolling temperature of
1200 0C. The heated billets are
rolled in 4 strand. No twist
continuous mill having a capacity of
8,50,000 tonnes of Wire Rod coils
and having the following
configuration.
- 7 stand two high 4 strand
horizontal roughing train.
- 6 stand two high 4 strand
horizontal Intermediate Mills.
- 2 stand 4 strand pre finishing Mill.
- 10 stand 4, strand. No twist
finishing mill.
The mill produces rounds in

5.5 - 12 mm range and re-bars in 8-12 mm range. The mill is equipped with standard and retarded stelmore lines for
producing high quality Wire rods in Low, Medium & High carbon grade meeting the stringent National &
International standards viz. BIS, DIN, JIS, BS etc. and having high ductility, uniform grain size, excellent surface
finish.

INTRODUCTION
The production capacity of crude steel in the world has increased markedly after the Second World War.
This increase has been possible through the establishment of larger plants and mill equipments. Wider applications
of converter (L.D) and continuous casting processes and introduction of extensive automation.
The very notion of continuous casting of steel dates back to Bessemer himself in his paper ingotless
casting, in the year 1858.
In 1933, Seigfried Junghans, the father of modern continuous casting developed and patented his mould
oscillation system that foundations were laid for large industrial scale application of the concast principle. In 1947
BISRA began considering casting with a spring suspended mould.
From the beginning of 1950s onwards continuous casting technology started developing at an ever
increasing rate. It is operational and quality problems for which Iron and Steel Industry initially showed limited
interest in continuous casting. But recently much work has been done in this line.
The process has tremendous potential and advantages which can be acquired from its use are so
considerable that today almost all new installations which are currently either under construction or in planning
stage is coming up with concast technology.
General overview of Steel Melt Shop:-
Basically the steel melt shop in VSP can be divided into two main divisions of huge importance. These are
LD Shop and Continuous Casting Department (CCD). The 1st one is to prepare the required grade of steel by treating
the hot metal, steel scrap with Oxygen, alloying treatment and by some other means. Whereas the 2 nd one deals with
rinsing (Ar.) the steel melt for homogenization, keeping required temperature and casting of blooms. For all these the
main divisions are also subdivided into several sections, as follows-
Steel Melt
Shop
LD
CCD
Shop
Ladle Secondary Gas Bloom

Converter Scrap
Mixers BMHS proper
Slag yard preparation Metallurgy Casters Cutting Storage
yard Bay area Machine Yard
Tundish ARS &

preparation
bay IRUT & LF

In steel melting shop of Visakhapatanam steel plant , LD process of steel making has been adopted. The
liquid steel obtained from LD process is cast into blooms through Continuous Casting Machines (Bloom Casters).
For better exploitation of the available facilities and to have efficient administration in the biggest dept. of
VSP ,Steel Melting Shop is divided into two major sections.
i) Converter Shop
ii) Continuous Casting Shop
Each of these has further facilities:
Converter Shop :
Bulk material handing section(BMHS)
Mixer Shop
Converter Bay
Scrap Yard
Slag Yard
Ladle preparation Bay
Continuous Casting Shop :

Tundish Preparation Bay (TP Bay)
Argon Rinsing Section (ARS) & IRUT & LF
Continuous Casting Machine
Gas Cutting Machine
Bloom Storage Yard.
DESCRIPTION OF THE FACILITIES
Mixer Shop
It is very difficult to supply the hot metal from BF to the converter as per its requirements unless
there is an arrangement for storing the hot metal in SMS. Mixer serves this purpose. There are two mixers
in SMS. The capacity of each mixer is 1300 THM. In mixer, temperature of the hot metal is maintained by
burning coke oven gas with air. The mixer vessel is in cylindrical form of two removable spherical ends.
Length of the vessel is 10.67m and dia is 7.64m. The mixer is installed on a mixer platform and is served by
mixer crane ( Two nose of capacity 180T/63T/20T).The main units of the mixer are:
shell assembly
roller support
tilting mechanism
hand brake mechanism
charging hole cover winch
charging hole platform
support door opening mechanism
gas and air distribution system
installation of the blower
lubrication system
electrical system.

The average life of mixer is about 1.6-1.8 MT, lining duration is about 30 days. To reduce abnormalities in
LD Steel making, Blast Furnace is supplying hot metal to SMS in the following temperature & composition range.
ELEMENTS C Si Mn P S
COMPOSITION 3.5-4.2 0.3-0.6 0.25 max 0.15 max 0.04 max
Temperature Range: 1250-1425 oC.

1250oC-1350oC through mixer route.
1300oC-1425oC through TLC (Torpedo Ladle Car) route.
Bulk Material Handling Section(BMHS)

The following bulk materials are used in in converter Shop of SMS.
Calcined Lime Dolo used as flux in LD converter.
BULK MATERIAL CaO +MgO LOI(Loss of Ignition) SiO2 Size

COMPOSITION 90-92% 5-7% 2.5% max 10-25 mm
Requirement = 6- 10 T as per heat weight and hot metal composition,iron ore lump use as Coolant in steel
making.
CONTENT Fe SiO2 Al2O3 MnO2

COMPOSITION 66.9% 0.9% 1.6% 0.05%
Size -15 60 mm.
Requirement =0.5-3 T as per blowing conditions.
Raw or calcined Dolo= Used to increase Lining life of converter.
Lump coke= used to preheat the lining of the new lined converter.
One of the requirements for continuous casting process is that the liquid metal should be killed (fully de-
oxidized ).For this and to make different grades of steel ,ferro alloys(FeSi, FeMn,SiMn etc) coke breeze /petroleum
coke and Aluminium are added in the ladle during tapping of steel from converter to ladle.
Converter Bay
Hot metal contains different of impurities (C, Si, Mn ,S,P) above safe level which make Pig iron brittle .But
steel is nothing but a refined hot metal. Refining is only possible when things are in molten condition. Refining
is done by O2 blowing in the LD converter Charges with Hot Metal, Scrap, Flux, Iron Ore etc. In this refining
process temperature of liquid steel is kept at 17000C (avg). Different grades of steel is made by adding various
ferro alloy & additives (FeSi, FeMn, Coke breeze or petroleum coke, Aluminium etc.) in different quantities
during tapping of liquid steel from converter to steel ladle.
There are 3 LD converters in SMS .Characteristics of converter is given below :
Capacity = 150 Tonne
Effective volume = 133 Tonne
Converter specific volume = 0.886 M3 /Tonne
Height to weight ratio = 1.36
Refractory for converter lining is MgO based e.g. Sea water Magnesia , Magnesia Carbon .Tar Bonded Dolomite
Bricks, pitch Bonded Dolomite Bricks etc.

Oxygen is blown in the converter through Oxygen lance. It consists of three concentrically arranged steel
tubes with connecting branches for Metal Flexible Hoses. Central pipe is for supplying oxygen , intermediate
pipe is for incoming cooling water and outside pipe is for outgoing water .At lower part of the lance there are 4
nos. Convergent-Divergent copper symmetrically arranged at 17.50 to the lance axis.
Characteristics of oxygen lance:
Lance Travel = 16000 mm
Oxygen working pressure = 16 KSCG
Water working pressure = 12 KSCG
No. of Nozzles = 5
Water consumption = 130 Cum/Hr
Oxygen flow rate = 400 450 NM3 /min
During blowing LD gas is generated .This is very poisonous gas because its main component is CO.
LD gas cooling ,cleaning and collection system comprises of tube bar-type of skirt .gas cooling hood and
stack, Closed loop type gas cooling arrangement with finfan cooler , kinapter ,gas dirt ,ID fan ,change over
valve, flare stack, gas holder etc. When the gas composition is acceptable ,it is recovered and collected in
gas holder .Unacceptable LD gas is discharges through flare stack.
LD gas cleaning system -Gas collection with suppressed Combustion.
LD gas cooling -Gas cooling with closed loop hot water pressurised cooling system.
LD gas cooling -Wet type cleaning system with adjustable throat venture.
Scrap Yard
Scrap is used as coolant. Scrap may be heavy (wt. up to 1.5 T) or light. Length should be less than 1.5 M.
Sometimes cast pig iron is used as scrap in case of shortage in steel scrap. Purpose of scrap yard is to supply
scrap to the converter periodically without any interruption. Following equipment are available in scrap yard.
1. Scrap Box Transfer Car.
2. Scrap Weigh Bridge.
3. Scrap Box.
4. Magnetic EOT Crane.
Scrap should not have dust ,moisture or water, grease, oil etc. Generally 15T of scrap is charged in each
heat.
Slag Yard
The slag generated in LD converter during refining of hot metal is collected in vessels called slag pots
(16/18 Meter cube capacity). This slag is dumped in the pits (4 nos.) which are present in slag yard. For
doing so, slag pots, slag pot transfer cars (3 nos.), slag dump cars (2 nos.), EOT cranes(2 nos.), etc. are
needed.

Ladle Preparation Bay
Ladles after prolonged use get worn out and need to be repaired. After one or two heats, plates for slide
gate control mechanism, for teeming liquid steel, need to be changed or repaired. All these and many activities are
done in Ladle Preparation Bay. There are 26 steel ladles and 4 hot metal ladles in SMS.
This bay will house the following main features:

Horizontal ladle Stand - For slide gate fixing ,plate changing etc.
Vertical ladle stand - For heating ladle
Relining pits - For relining ladles
Ladle drier - By burning coke oven gas ,ladle is heated
EOT Crane(3 nos) - To handle the ladle
(main hoist capacity 100 T)
On line drier - To heat the ladle before releasing for tapping
Argon Rinsing Stations(ARS):
The liquid steel which is tapped from LD converter is not homogeneous in composition and temperature
.To make the liquid steel suitable for continuous casting purpose by making it homogeneous ,inert gas rinsing is
done .Generally Argon gas is used for this purpose . Both bottom and top purging facilities are available. Bottom
purging is superior than top purging. When both are applied, it is more effective.
In general ,12 minutes rinsing is done. For all the 3 converter steel transfer car track,3 ARS are available .In case
of LD-2 steel transfer car truck, IRUT(Injection Refining & Up Temperature) is available .Along with steel
temperature rising ,Argon Rinsing is also done simultaneously Aluminium is added.
In ARS ,Aluminium is added for complete de-oxidation (to reduce Oxygen potential of liquid steel below 15 ppm)
and to increase Al % in liquid to make it suitable for continuous casting purpose.
There is one ladle furnace in ARS bay .In ladle furnace composition adjustment and liquid steel
temperature raising can be done .Simultaneously Argon Rinsing is also done along with the above said activities . In
Ladle furnace ,temperature of liquid steel is raised by electric arcing there are 3 graphite electrodes for this
purpose.
When rinsing is over after achieving desire temperature and composition (Varies from one steel grade to
another)ladle covering compound is added at the top layer of liquid steel in the ladle. This reduces heat loss from
the ladle.
Tundish preparation bay:
Tundish is a refractory lined container having 4 nozzles through which liquid steel is poured in all four
moulds of a CC machine at a time. Pouring of liquid steel from tundish to mould is controlled by stopper rod
mechanism. During casting, tundish is placed over a mould and below steel ladle. Tundish maintains the constant
ferrostatic pressure and it helps in floating of the non-metallic inclusions at the top layer of the liquid steel and thus
non-metallic inclusions are prevented from entering into the mould.
In tundish preparation bay, used tundishes are cooled by water or compressed air and lining is demolished.
All the relining activities, stopper rod assembly fixing etc. are done in this bay.

Continuous Casting Machines(CCM)
Continuous casting may be defined as teeming of liquid metal in a mould with a false bottom through which
partially solidified ingot (same shape as mould) is continuously withdrawn at the same rate at whixh liquid metal is
poured in the mould.
Facilities and equipments at CCM platform: Lift and turn stand

To accommodate the steel ladles and place them in casting position as and when required to facilitate
sequence casting. It lifts the ladle and places he ladle at the casting position by turning it and swing back the empty
ladle after completion of casting.
Mould oscillating system:

To facilitate easy withdrawal of concast blooms (partially solidified) from the mould.
Oscillation frequency : 60-100 cycle/minute .
Mould oscillation amplitude :6-8mm.
Copper mould:
The foremost important factor in the continuous casting is the copper mould which decides the efficiency of
the process. The material selected for mould and the design of mould play a prominent role in obtaining the bloom of
greater surface finish, better mechanical properties with minimum casting defects. A mould with good design
associated by good cooling system gives quality blooms, provided a great care, is exercised during casting.
In VSP, square(250mm x 250mm) and rectangular( 320mm x250mm) cross-sectional moulds are used.
These moulds are provided taper towards the bottom(327 x 255 top,324 x 252.5 bottom in case of a 320 x 250
bloom) to maintain the contact between partially solidified strands and it is made of copper which is necessary for
achieving the necessary cooling rate.
Copper is an ideal material for mould because it is having-
1. Good thermal conductivity.

2. Mechanical strength must be retained at operating temperatures 250oC.
3. Recrystallization temperature above 300oC.
4. Low friction co-efficient and good resistance to wear.
5. Chemical immunity with reference to Steel
Cu-Ag 0.1 P-F 25-possess all the above properties.
Length of mould at VSP is 1.0m

Radius of mould 12m
Strand Cooling:
Strand cooling is carried in two stages: Primary and Secondary cooling.

Primary Cooling:
The boiler feed water is used for this purpose with pH 7-9, total hardness-0.2dh. this water is repeatedly
pumped through the mould in a closed cycle with re-cooling blot. This water has to be treated and anti-corrosive
agent etc. , should be added. This water is supplied at a pressure of 4-5 bar. The inlet water comes from the bottom
and leaves the mould through the outlet valve which is located at the top of mould. This is indirect type of cooling.
Secondary Cooling
The water that is spread over the strand should cool the strand uniformly throughout the length to avoid
undercooling of some parts of the strand. The pressure will be 6 bar. The counteracting flow problem due to
corrosion, the pipeline will be made of stainless steel. In secondary cooling, strand (bloom) will be completely
solidified leaving no liquid steel at all. The secondary cooling zone begins from just below the mould.
Water for secondary cooling should have
pH :7-9
Total Hardness :20dh.
Carbonate hardness :0.7dh.
Dummy Bar
The function if dummy bar is to seal the mould bottom, for the starting of casting and to withdraw solidified
shell until the hot strand has passed to strengthening and withdrawing machines.
Backup Roller Sections N1 & N2

These sections are intended for supporting and directing the dummy bar and strand in course of casting. N1 is
a four roll section installed on post underneath the secondary cooling sections while N2 is a six roll section installed
after the four high strands.
Withdrawal and Strengthening rollers

There are 4 strands which are used withdrawing and strengthening the curved bloom. These 4 strands are
designated as TK1, TK2, TK3, TK4.
TK1 :4 high strands.
TK2 : 2 high strands.
Technical details of CC machine

Average casting speed for 320 x 250 bloom size is 0.78 M/min for 250 x250 bloom size is 0.82 M/min.
Gas Cutting Machines(GCM):

The strand which continuously comes from the copper mould after getting completely solidified ,should be
cut as per our requirement ,to facilitate easy handling etc. In order to cut the blooms accurately , a gas cutting
machine, using LPG , is used.
Since the bloom travels with certain speed ,the machine used for cutting for the bloom .For this gripper are
used ,which grips the bloom and travels along with it ,taking the LPG flame with it .Each CC machine has been
provided with 4 cutting machines to cut the four blooms at a time.
Bloom storage yard (BSY):

To synchronise the production in continuous casting machine and requirement of rolling mills for blooms,
Bloom storage yard(BSY) has been established. Inspection and selective conditions are also carried out in BSY. After
cutting the blooms the at GCM they are moved to cooling beds and after cooling to 5000C they are transferred to

racks. The BSY is served by 11 nos. EOT cranes with rotating cabins and magnet facility .Blooms of particular grade
of steel are stored at a particular place. Every bloom is marketed by heat no. and machine no.
Principles of continuous casting process
Continuous casting may be defined as teeming of liquid metal in a short mould with a false bottom through
which partially solidified ingot is continuously withdrawn at the same rate at which metal is poured in the mould. The
equipment for continuous casting of steel consists of :
1. The ladle to hold steel for teeming.
2. The tundish to closely regulate the flow of steel into the mould.
3. The mould to allow adequate solidification of the product.
4. The withdrawal rolls to pull out the ingot continuously from the mould.
5. The bending and/or cutting devices to obtain hand able lengths of the product.
6. The cooling spray to solidify the ingot completely.
7. The auxiliary electrical and/or mechanical gears to help run the machine smoothly.
The mould is open at both ends and is water cooled. The operation is started by fixing a dummy plug-bar to
temporarily close the bottom of the mould. Steel is slowly poured into the mould via a tundish and as soon as the
mould is filled to a certain level withdrawal of the plug begins. The rate of with drawl must match with that of
the pouring for smooth operation of the machine. Uninterrupted pouring and simultaneous withdrawal gives rise
to the whole cast being poured in the form of one piece which may be cut into smaller pieces as per the
requirement.
In order to expedite the process ingot does not solidify completely in the mould. As soon as sufficiently
thick skin, which will be able to stand the pressure of the liquid core, is formed, the withdrawal from the mould
commences. It is then cooled by secondary cooling. A small area of the ingot, where the liquid core is able to
press the solid skin against the mould walls, maintains a short of seal to prevent liquid from leaking out from the
mould. This act as a moving seal if the bar is withdrawn slowly from the mould and an equivalent amount of
liquid steel is poured in.
If the bar is withdrawn rapidly this seal may fracture and may produce cracks in the ingot or even breakouts.
Both of these eventualities can be eliminated and the casting speed can be increased if a moving mould is
adopted rather than a stationary mould.
The principle of moving the mould is known as Junghams principle so named after the investigator. In this,
the mould is moved up and down variously through a stroke of 12 to 40 mm. The ratio of speed of downward to
upward stroke is nearly 1:3. The downward speed being equal to that of the speed of withdrawal. If the
downward is even slightly less than that of the rate of withdrawal major transverse cracks are formed. In a later
modification therefore, the downward speed has been increased to little more than the rate of withdrawal. This
results in negative stripping of the ingot and is beneficial in following ways:
1. The initially crystallised skin of the ingot is further compacted.
2. Formation of tensile stresses is prevented and even compressive stresses may be developed in the
initially solidified skin.
3. It particularly eliminates the possibility of transverse cracking of the skin.
4. Transverse cracks that may be formed earlier are liable to be welded again.
5. It allows maximum rate of withdrawal i.e. maximum from a given machine.
The solidified strand is taken out from the mould by withdrawal roller and then the strand is subjected to
straightening roll section, where it is made horizontal. In the next operation the cast object is cut
generally by using LPG gas to the required size and sent to storage yard.

The Continuous Casting Machine
The continuous casting machine can be divided into three regions:
1. Water cooled copper mould section (A)

2. The secondary cooling section (B)
3. The radiant cooling section (C)
The description of the various parts is as follows:
A. The Mould:
The mould is the heart of the continuous casting machine. It is the primary heat extraction device
where a shell of adequate thickness is formed. The mould also provides support to the newly formed shell.
It influences, profoundly, the quality of the steel. Design which does not suit the operating conductions or
excessive distortion in the mould that may develop in the course of prolonged operation have been found to
increase the number of defects. Eg. The longitudinal corner cracks etc.
Different types of moulds have been developed like the straight mould and curved mould. The three
major types of moulds are :-
1. The solid block mould.
2. The plate mould which consists of a copper mould backed with cast iron plates.
3. The tubular mould.
The heat transfer in the mould occurs in a series of steps:-

1. Conduction and radiation across the air gap separating the mould and the strand.
2. Conduction through the mould wall.
3. Convection at the mould/cooling water interfaces.

The moulds are reciprocated during casting. The principle was first developed by Junghans to reduce the
risk of breakout caused by the rupture of the skin. With the introduction of Negative Strip high speed
casting became possible. Negative Strip means that on the down stroke the mould moves at a higher velocity
than that of the withdrawing strand. This process prevents mould strand adhesion and averts rupture of the
shell during subsequent upward motion of the mould. Another major advantage is that the mould lubricant,
from the top of the mould, is transferred to the lower sections.
B. The Secondary Cooling Section:
This section follows the mould in the continuous casting machine. The secondary cooling section consists of
support rolls and water spray nozzles. The rolls primarily give support to the thin shell that forms in the mould. The
water sprays continue the heat extraction process that is initiated in the mould. This section varies from as little as
.4 m up to 4.0 m.
The water sprays operate on the principle of pressure atomisation that is water under high pressure when
forced through an orifice breaks up into droplets. The sprays used generally give a full cone pattern. Sometimes a V-
pattern is used for the lower portion of this section. Generally for bloom casting sets of four nozzles, one for each
face, are placed in rows. These nozzles are connected and classified into zones so that the water flow rate and thereby
the heat extraction rate may be controlled.
As a major part of the shell forms in this section the heat extraction and solidification should be continued at
a controlled rate without the generation of tensile stresses of magnitude that may cause shape defects, surface cracks
or internal cracks. Water flux has a major effect on heat extraction. But the conduction of heat through the shell
becomes the rate limiting process. The primary effect of spray cooling is to alter the temperature distribution through
the shell.
Improper spray pattern cause a large no. of defects in the blooms. The most common defect is the midway
crack. The other defect though not as common, is rhomboidity, which arises due to a symmetrical cooling pattern as a
result of clogged nozzles etc.
C. The Radiant Cooling Section :
This section follows the secondary cooling zone. The strand is left open to the atmosphere. There is no
control over the solidification or the heat transfer rate in this zone.
The Gas Cutting Machine :

This is the last part of the machine. It follows the radiant cooling section. The function of this section is to
cut the strand into blooms of the desired length.
The gas cutting machine is a welded steel construction wherein a gas torch is fixed. This torch is mounted on
a car which moves along with the strand. The car is provided with grippers are pneumatically operated. The torch is
provided with transverse movement. When the strand moves up to the desired length the gripper is engaged. The
strand and the gas cutting torch move with the same speed. The cutting LPG is switched on and the torch is moved in
the transverse direction cutting on the strand. When the cutting is completed the bloom is taken away by operating
the withdrawal rolls and the gas cutting machine is brought back to its initial position.
Different types of Machine:-

Vertical type:-
It is the first continuous casting system where in the mould and the discharge are both vertical. Liquid steel is
brought to the machine in a stopper controlled ladle and is teemed in a stopper controlled tundish which regulates the
flow of steel to the mould. Below the mould is secondary cooling zone in which rollers are set to make close contact
with the ingot. The water spray nozzle is interspersed in between the rollers. The no. of sprays, pressure of water etc.
are adjusted to control the degree of cooling .It is also known as a roller apron. The main withdrawal rolls are situated
just below the roller apron. The cut off torch travels at the same speed as that of the withdrawal by clamping the
product. After cutting, the torch goes back to its position quickly. The product is then laid horizontal and is hoisted
to the normal floor level.
This type of plant is very tall and hence needs either a tall shop or a large pit to accommodate the equipment.
The problem is acute if high casting speeds are employed and in consequence longer cooling zone is required. This
type of plant is therefore used for larger medium sections. It is good for slabs where in bending is avoided for its
adverse metallurgical effects.
In the event of breakdown it is easy to repair and restart the machine. It is most simple in construction and
most reliable to operate. All steel qualities can be cast and those too high speeds without fear of damage to strand by
bending.
The vertical Mould Horizontal Discharge Type :-
This is a modification over the earlier vertical design to reduce the overall height of the machine. The mould,
roller apron design & pitch rolls are similar to those in a vertical machine. After the product emerges from the pitch
rolls it is bent to obtain the discharge horizontal. The cutting torch moves horizontally. A horizontal set of
straightening rolls becomes necessary. A saving of 30% in height is thus possible by this design. The floor space
requirement is however more. In the event of a breakdown it is more difficult to repair and restart then the vertical
machine. This is quite popular for small and medium size cross-section.
The curved mould type(S-Type)

In this the mould itself is curved and it oscillates along the same curved path as the axis of the product. The
withdrawal rolls carry out the bending also and hence need to be adequate strength. The height of this shop in this
case is still less and hence it is called as low head type machine. The bending of the ingot commences even before it
is entirely solid in cross-section and hence large sections can also be cast without much of bending problems. It is
quite popular for medium size sections. The radius of the curvature should be as high as possible. In the event of a
breakout it is very laborious to remove the curved ingot from the machine and restart the operation.
Horizontal continuous casting machine
Steel is poured from the ladle into the tundish and flows horizontally in the mould by a refractory
connection( break ring) on the side of the tundish. Partially solidified shells are withdrawn in a pull and pause or pull
and push cycle, through a secondary cooling zone where solidification is completed. The solidified shell is then cut
into lengths and sent to cooling beds.
Advantages:
Lower investment cost

Low height and small space requirements.
Less labour requirements.
Less ferrostatic pressure which minimizes strand bulging and inside tears.
Absence of metal re-oxidation between tundish and mould.
Shorter metallurgical length.
No bending of the strand which permits the casting of crack sensitive products.
Rotary casting machine:-
It is different from other casting machine; in that it has a revolving mould. A water cooled copper ring serves
as the mould. In the casting area this ring is closed by a movable steel belt , so that cavity is formed. The steel
belt is removed by a 90o turning of wheel. The strand is straightened in an un bending zone. The circumferential
speed of the wheel is 4 7 m/min. in order to strand from the wheel the mould has a trapezoidal shape.

Advantages:
Casting speed can be increased to high value.

Yield is more (99%).
Energy saving is more.
Operational costs are less than conventional casting.
General features of Continuous casting machine at VSP:-
In VSP there are 6 (3 in stage I and the other 3 in stage II). Continuous casting machines in continuous casing
shop. The machines are of radial type in the straight mould. The machines are slated to operate in sequence for ten
heats.
TECHNOLOGICAL CHRACTERISTICS OF VSP MACHINE
Sl no. Characteristics Bloom casing machine

01 Machine Type Radial
02 Machine radius 12 M
03 No. of strands 4
04 Ladle capacity 150 T
05 Tundish capacity 25 T
06 Metallurgical length 10 M
07 Max. casting speed 1.2 M/min
08 Dummy Bar type Link
09 Avg. length of cast blooms 6M
10 Sections Cast 250 X 250 mm, 250 X 320 mm
11 Casting time for a heat 100 min
12 Water consumption in the mould 110 140 M3/ hr.
Effect of various parameters on the quality of bloom:-
1. Casting temperature
Liquid steel during continuous casting should be within the specific limits depending up on the grade of steel.
A 30-40 o C above liquidus temperature and high casting speed are required for good equiaxed cast structures
increase in casting temperature above the desired level leads to central segregation and formation of longitudinal
cracks. Higher the casting temperature longer will be the zone of columnar crystal and vice versa.
2. Casting Speed
It is well known that the depth of liquid pool increases as the withdrawal rate increases and that for a
given cast cross-section and steel composition , there is a limiting rate of solidification that must not be
exceeded if central soundness is to be maintained. Increasing the cast speed reduces the residence time in the
mould, thereby decreasing the solidification rate. This will result in an increase in the time required for the

removal of superheat, delaying the nucleation and growth of equiaxed crystal, increasing the columnar zone
and increasing the extent of axial segregation.
The casting speed is related to the thickness of solidified skin of the ingot at the bottom of the mould
according to following relation.
S = K/
Where S = thickness of solidified skin.

K = solidification constant varying from 2.3 2.9 cm.min1/2 depending upon the grade of steel.
Lm = length of mould
V = casting speed in cm/min
From this relation it can be seen that higher casting speed results in a thinner and hotter skin , which is weaker.
In VSP the casting speed is regulated according to the casting temperature as shown in the table-
toC 1530 1535 1540 1545 1550 1555 1560 1565 1570 1575
v 0.85 0.80 0.75 0.70 0.65 0.60 0.55 0.50 0.45 0.40
M/min
Norm for increasing the casting speed of the continuous casing machine at VSP:
Casting speed Length of the bloom cast

Old mould New mould
0.2 M/min Upto 200 mm 400 mm
0.8 M/min Upto the end of the casting

Casting Powder
Casting powder is the type of mould flux. This are synthetic slag forming composition which are required to
perform a no of functions.
1. Thermal insulation This will prevent bridging / solidification of steel in the mould. The insulation is
provided by un reacted flux over the meniscus.
2. Prevent reoxidation- insulation of the steel from the atmosphere.
3. Absorbs inclusions- the flus assimilates this material and forms lower melting point, compounds which flow
out of the mould with the flux. The chemical composition of the flux determines its ability to absorb
inclusions.
4. Lubrication- Between solidifying shell and mould wall is determined by viscosity and crystallisation
temperature.
5. Uniform heat transfer- between the solidifying shell and mould wall. Occurrence of localised non-uniform
heat transfer will usually results in crack formation. Flux viscosity and crystallisation temperature are
determining factors.
Application of flux:-
1. To provide optimum insulation a dark flux practice a layer of 15 20 mm of unmelted flux should be
maintained.
2. At frequent interval nearly 0.7 0.8 Kg/Tonne of steel should be used.
3. Chilled slag rings are required to be removed a trouble free operation.
Typical composition of casting powder at VSP

Flux parameters:-
Chemical composition:-
CaO 28 32
SiO2 31 34
Al2O3 58
Na2O + K2O 68
F 45
C 14 - 16
Viscosity at 1300o C = 4-5

o
Melting range (20 C)
Softening point(T1) 1050
Melting point(T2) 1140
Flow point(T3) 1160
Casting Parameters:-
Casting speed 0.2 1.2 m/Min

Section mm 250 X 250
250 X 320
Steel grade Low carbon

Abnormalities in Continuous Casting Process :
From industrial point of view continuous casting process mainly faces three types of abnormalities of serious
concern. These are as follows,
1. Running Tendency
2. Break out
3. Chocking/Clogging
Details of the abnormalities :
Running Tendency:
This problem occurs mainly in the tundish, while pouring the metal from the tundish to the mould. It
deals with the corrosion of the Stopper Rod and sometimes of different precipitation occurring at the junction of
Stopper Rod-Submerged Entry Nozzle.
The main reasons behind Running Tendency can be of four types.
1. High temperature erosion

2. Erosion due to high Oxygen content
3. Precipitation of Aluminium, for high of its presence
4. Precipitation at low temperature.
1.High Temperature Erosion :-
This occurs due to interaction of hot metal with the rod. The stopper rod is used to control the metal flow
from the tundish to the mould. For high quality controlling the rod must close the Submerged Entry Nozzle (SEN)
with almost no flow characteristics. So during controlling of flow when the molten metal with high heat content
flows at high speed through the SEN it erodes the cone type structure of the rod facing to the. Due to this while
further controlling of the flow the rod fails to close the SEN properly, leading to unstoppable metal flow to the
mould.
Influencing Factors :-
1. Casting Temperature: When the metal in the tundish is handled over a superheat of 20C than the desired
level (desired level is 30C to 40C over the liquidus temperature) then the stopper rod is very much
susceptible to erosion. And casting temperature is also in relation to the no. of strands working properly to
cast. The lesser the no. of working strands, the higher the requirement of casting temperature. .( Data Table.
1)
Remedial Measures:-
1. The temperature must be at desired level, not much higher than that.
2. The temperature must be controlled depending on the no. of strands working properly.
3. The speed of flow should be controlled at an optimum rate depending on the temperature of casting.
2.Erosion due to high Oxygen content :-
During preparation of steel it consumes a large amount of Oxygen. So, the bath must be killed properly,
otherwise Oxygen will erode the MgO-C bricks of the refractory lining by reacting with the C. It may also help to
corrode the stopper rod.

Influencing Factors :-
1. Improper Killing of the Bath:

a) Mainly Al is used to deoxidise the bath. If by any means it is very much less than the required level, then
Oxygen i.e. absorbed in the bath will help to corrode the stopper rod very easily.
b) Si is added to the bath as Fe-Si, Si-Mn for deoxidation of the bath. It should be in the range of 0.15-0.3% in
order to deoxidise the bath completely. If it is present below 0.1% then complete deoxidation will not be
achieved with low Aluminium levels. So it leads to higher erosion by Oxygen. (Data Table. 2)
c) If the rinsing is not done properly then for less homogenization of the bath killing doesnt occurs properly.
d) Higher C content may help to kill the bath but that also requires higher rinsing i.e. homogenization.
2. Casting Temperature: The higher the casting temperature, higher will be its reactive power for erosion.
(Data Table. 1)
Remedial Measures:-
1. The bath must be killed very efficiently, and checking of Al, Si levels should be done accurately.
2. Rinsing must be optimised depending on the C, Al, Si content.
3. Casting temperature must be controlled properly.
3. Precipitation of Aluminium for high of its presence:-
Aluminium is added to deoxidise the steel, if excess aluminium remains in the steel it will be get precipitated
at the nozzles. Thus the stopper rod cant close the nozzle properly.
Influencing Factors:-
1. Rinsing has not been done properly.

2. Casting temperature is lower than the requirement.( Data Table. 3)
3. Higher Aluminium content.( Data Table. 3)
Remedial Measures:-
1. Rinsing must be done properly, depending on the Oxygen and Al content.

2. Casting temperature should be controlled with right precision, otherwise it will help the Aluminium to be get
precipitated.
3. Aluminium powders, which are further added at IRUT (Injection Refining up Temperature) for controlling
the Al content and production of chemical heat during treating with Oxygen, must be added in appropriate
measurement.
4. Precipitation at Low Temperature:-
When the temperature is very much lower than the desired level then it leads to easy precipitation of the
alloying elements, slag, inclusions etc. it is sometimes also called cold running.
1. Casting Temperature: The temperature is very much lower than the desired level. ( Data Table. 3)

2. Mn/Si Ratio: Mn/Si ratio in the steel has a direct effect on the MnO/SiO2 ratio of the slags obtained and as a
result also on their precipitation conditions. When the Mn/Si ratio in the steel reduces, the amount of Si in the
slag increases as do the melting point, surface tension and viscosity. With a low Mn/Si ratio and unsuitable
temperature trends slags are obtained which are precipitated in the mould.
3. LCT: LCT or Ladle Cycling Time, if it is much higher than the desired one(around 1hour 15 mins) then
temperature drop occurs, leading to precipitation. ( Data Table. 3)
4. Rinsing: Rinsing time must not be very much higher. Otherwise melt temperature would be reduced.
5. Argon Superheat: It should be controlled very much precisely to keep the nozzle mouth free from any
precipitation. ( Data Table. 3)
Breakout
A major problem that may occur in continuous casting is breakout. This is when the thin shell of the strand
breaks, allowing the still-molten metal inside the strand to spill out and foul the machine, requiring a turnaround
(metal supply afterwards be guaranteed to avoid unnecessary shutdowns and restarts).
1. Initial shell formation and oscillation effect

Early solidification in continuous casting occurs in the form of partial freezing of the meniscus curvature
originating from the mould liquid contact point. Prevention of sticking and tearing of this initial thin shell during the
descent of the solidifying strand is one of the major functions of the CC mould. To minimise shell sticking and
tearing, friction between the strand surface and mould wall must be kept below a critical level depending upon the
shell strength. Sticking of the shell in the mould often occurs in a high-speed continuous slab casting machine.
Apparently the sticking occurs at the meniscus where heat extraction is the greatest and molten mould flux flows
between the shell and the solid mould flux rim oscillating with the mould. The main features of the oscillation cycle
prevalent now are depicted in figure 1a. The figure represents the evolution of the mould velocity in one cycle under
the sinusoidal mode. From the lubrication point of view, the oscillation cycle translates into two operating phases as
below.
(1) A compression phase of duration tN defined as the negative strip time where mould slag is infiltrated into the gap
between the first solidified shell and the mould. The period tN witnesses a higher downward velocity of the mould
relative to descending velocity of the strand (Vc) and is responsible for the release of the shell from the mould wall.
(2) A lubrication phase of duration tP where tensile stresses are applied to the first solidified shell accompanied by
deposition of the infiltrated mould slag against the mould wall. This corresponds to upward movement of the mould.
Effect of oscillation in terms of friction pattern during upward and downward stroke is shown in figure 1b
(Brendzy et al 1993). The measured load cell response indicates the friction pattern under sinusoidal oscillation, i.e.
high friction during upstroke and minimal friction centred about the negative strip time. Loss of friction during tN
suggests decoupling of the shell from the mould wall. Figures 1c & d (Takeuchi et al
1991) also show results of various other changes caused by oscillation, e.g. mould slag pressure and inflow rate of
slag.

Mould oscillation results in formation of oscillation marks (OM) at near regular intervals on the surface of the cast
product. These marks may be accompanied by formation of solidified hooks beneath the oscillation marks as shown
in figure 2.
Formation of oscillation marks basically comprises three main stages.

Partial solidification of the meniscus against the mould wall and the mould powder in the form of a fragile
hook.
Bending of the hook during tN and healing of any shell tear (caused by viscous drag in the preceding
upstroke). The segregation line shown in figure 2 is attributed to shell bending, where the solute-rich inter
dendritic liquid is squeezed out to the surface (Harada et al 1990). The origin of shell bending in slab casting
is variously traced to:
Collision of slag rim with top of the solid shell (Tada et al 1984).
Pressure of infiltrating molten mould slag (Takeuchi & Brimacombe1984).
Shell unbending during upstroke by viscous drag (Wolf 1991a). The upstroke may also be associated with
overflow of liquid metal over the bent hook in case of strong meniscus shell or mould level rise. A
combination of shell unbending and metal overflow is also possible (Saucedo 1991). The oscillation marks
tend to be deeper in case of shell unbending, while these are shallow and show lapped surfaces when
overflow occurs.
Various types of oscillation marks and hooks encountered in slab casting as mentioned above are shown in figure
3. It is evident from the figure that the shape of hook and oscillation marks is basically linked to the extent of shell
bending/unbending and overflow over the meniscus during casting.
1.1 Lubrication mechanism in the mould

Lubrication in the slab mould arises from the infiltration of mould slag into the strand mould gap. The
layering of the slag in the gap is shown in figure 4. The friction in the mould is considered to originate from two
mechanisms. The motion of the mould relative to the solidified shell gives rise to a frictional force due to the
viscosity of the slag film. The frictional force generated through this mechanism, termed liquid friction fl is given by
(1)
where, Vm = mould speed, Vc = casting speed, h = viscosity of liquid slag film, and dl = thickness of slag film.
If relative movement occurs between the strand and the solidified mould slag, the friction force is generated by solid
solid contact. The resulting solid friction fs is expressed as
(2)
where hs = coefficient of solid friction, and H = ferrostatic pressure of molten steel.
The relative influence of fl and fs along the mould length is shown in figure 5, (Suzuki et al 1991). The figure
shows that liquid lubrication (fl) dominates completely in the upper part of the mould. On the other hand, the value of
the solid friction fs is lower than fl at the lower part of the mould indicating dominance of solid lubrication.
The figure also brings out the role of slag viscosity in determining the zone of influence of fl. With lower
slag viscosity the zone of liquid lubrication extends further into the lower part of the mould. The friction concept as
mentioned above is useful in explaining the increased tendency of sticker breakout with increase in casting speed. A
comparison between calculated tensile stress on the solidified shell and high temperature strength of 0.1% C steel is

made in figure 6. The tensile stress, sf, applied to the solidified shell at location, Z, from the meniscus is calculated
using (Suzuki et al 1991).
where F = frictional force (fl or fs) per unit area whichever is lower, and Ds = thickness of solidified shell at Z.
Figure 6 shows that sf exceeds shell strength sb at 5 cm from the meniscus with a casting speed of 18
m/min, indicating that sticking type breakout may occur. Friction analysis indicates that prevention of sticking type
breakout in high speed casting requires improvement in the lubrication in the upper part of the mould, particularly
just below the meniscus. Since liquid lubrication completely prevails near the meniscus, the optimum casting
conditions can be ascertained using (1). As the equation indicates, this calls for consideration of mould slag
properties (viscosity and solidification temperature), as well as the oscillation parameters.
1.2Mode of oscillation
The analysis in the previous sections indicated the important role of oscillation parameters, e.g. negative strip
time (tN) and mould up time (tP) on initial shell formation and friction control. These parameters, under more
common sinusoidal mode of oscillation, are defined by.
tN = (1/pf )cos1(Vo/phf),
tP = to. (4)

The expressions for tN, tP show that the sinusoidal mode is characterized by only two independent
parameters such as stroke and frequency. These two degrees of freedom are not sufficient to optimise independently
the duration of tN and tP. In order to separate the lubrication function and the compression on the solidified shell, the
triangular mode of oscillation is steadily gaining ground (Darle et al 1993). The triangular mode permits control of a
third parameter, i.e. triangle distortion, defined as,
(%) = (tP/tC) 100. (5)

The features of this oscillation mode are shown in figure 7 indicating longer upward motion as compared to
downward motion. The duration of up motion (i.e. tP) can be regulated as per requirement by adjusting distortion
ratio (). Consequent to longer tP, the relative speed of the mould to the solidifying shell decreases resulting in
reduced friction. Comparison of measured mould friction between sinusoidal and non-sinusoidal mode on a pilot
caster is shown in figure 8 (Wolf 1991a). Finally it may be added that the concept of non-sinusoidal motion, though
known for long, is only now finding application in commercial slab casting with development of the hydraulic
oscillation mechanism (Hoedle et al 1999).
1.3 Early solidification performance

The performance of the oscillation and lubrication process in slab casting is primarily indicated by oscillation
mark depth, hook depth and powder consumption. Salient features of these indicators are discussed below.
1.3aOscillation mark depth: This mark in itself is a surface defect and its severity may prevent hot rolling without
prior grinding in special grades such as austenitic stainless steel. Increased thermal resistance at the bottom of mark
reduces local cooling rate which retards shell growth and coarsens local microstructure. Such coarse microstructure
enhances susceptibility for transverse surface/subsurface cracks, particularly in peritectic steel grades (Wolf 1991b).
The most critical factor controlling mark depth is steel composition. The strong meniscus shell of peritectic steel
grades (about 01% C) and austenitic stainless steel (Ni/Cr ratio = 055) leads to most pronounced mark formation.
In higher carbon steels with weak meniscus shells, on account of enhanced microsegregation, oscillation marks are
much less severe. The composition dependence of mark depth is rationalised in figure 9 (Wolf 1991b), where the
effect of the carbon percentage on phosphorus

segregation and mark depth are shown. The other factors associated with oscillation mark formations relate to the
mechanism of shell bending and unbending mentioned earlier. Mark depth is enhanced due to the inward bending of
the meniscus shell during the down-stroke due to the flux pressure of the liquid slag. Calculated flux pressure
distribution during the downstroke showed that down-bending during the whole period of negative strip is decisive,
while the instance of maximum velocity is not. In practical terms, mark depth can thus
be correlated to tN and powder consumption. Higher consumption causes deeper marks on account of larger flux
volume driven during down-stroke.
1.3b Hook depth: As compared to oscillation marks, hooks (figure 3) are more subtle defects, and largely affect
subsurface cleanliness of low to ultra low carbon steel slabs. The effect of the hook shows up in the form of slivers in
the vicinity of coil edges (rolled slab) corresponding to slab corners. For very low carbon grades
(%C 001%), the slivers may appear in the centre of the coil width as well (Darle et al 1993).
The geometry of the solidified hooks varies according to casting conditions as explained in figure 3. Hooks
reciprocating the meniscus shape (figure 3a) and to a lesser extent, straight hooks (figure 3b), act as carriers of mould
slag into the slab subsurface (up to about 2 mm). Subsequent metal overflow embeds these in the solidified shell. In
the case of bent or folding hooks, on the other hand, slag adhering to the meniscus shell returns to the surface and
does not undermine slab cleanliness. Hook formation is highly sensitive to carbon content of steel on account of low
liquidussolidus gap, and predominantly occurs in corner regions of slabs which encounter stronger mould cooling.
In the case of ultra-low carbon grades, hooks appear in the slab midface regions also (Darle et al 1993). The hook
defect which arises from overflow of the meniscus shell requires close control of metal level in the mould.
Oscillation parameters also influence hook depth. Non-sinusoidal oscillation is shown to be an effective tool for
improving slab subsurface cleanliness. The combination of lower inward bends (low tN) and higher outward bend
(high tP) accompanying high triangular distortion provides additional means to control hook geometry.

Inconsistent temperature and casting speedhigher the superheat of the liquid steel,lower is the thickness
of the shell formed. Due to the ferrostatic pressure exerted by the flowing metal in the mould, bulging takes
place and as the shell does not possess sufficient strength, breakout occurs. Inconsistent and inhomogeneous
temperature has a big influence on the cause of breakout. As casting speed increases, the occurrence of
breakout increases since mould lubrication becomes insufficient due to lack of mould flux flow from
meniscus into the solid shell boundary. Also increasing casting speed results in decrease of the total heat
removal. Often breakout is due to too high a withdrawal rate as the shell has not had the time to solidify to
the required thickness, or the metal is too hot, which means that final solidification takes place well below
the straightening rolls and the strand breaks due to the stresses applied during straightening. For a fixed
carbon content of the steel, higher temperature and higher speed combination influences breakout
occurrence.
Any change in the oscillation setting for reducing the oscillation mark severity through increasing the
oscillation frequency that increases the speed of the mould thus increasing the friction at the interface risk
breakout occurrence.

Improper lubrication between the mould and the strandpoor quality of casting powder if used gets
entrapped in the molten steel below the meniscus resulting in improper lubrication between the mould and
the strand causing sticking of the strand which possesses difficulties in withdrawing from the mould resulting
in discontinuity in the strand leading to hanging breakout. In case of a billet casting, the shell sticks to the
mould due to inadequate or uneven lubrication affecting the heat transfer causing sticker breakout.
Ineffective water flow in the mouldAny decrease in water flow to the mould leads to lowering of heat
extraction leading to formation of very thin shell ultimately resulting in breakout. The difference in inlet and
outlet water temperature, pressure and flow rate has a bearing on the mould cooling. Choking in the mould
cooling system leads to increase in pressure and reduction in flow rate affecting heat extraction and breakout
occurrence. Also the large difference in inlet and outlet water temperature results in sticking of the strand in
the mould leading to breakout.
Improper mould geometrymoulds are provided with a taper to accommodate the shrinkage of the steel on
solidification for increasing the metal mould contact area and thereby increasing the heat extraction from the
mould. Increasing heat extraction increases the shell thickness in case of a conventional mould with linear
taper with high speed billet casters, the heat transfer at the meniscus level rapidly produces a solid shell with
shrinkage of the shell cooling the corners off the mould stopping heat transfer and at the bottom portion of
the mould shell growth continues except at corners where re-melting takes place. When the shell leaves the
mould, the shell temperature shows considerable variation and application of increased casting speed during
this time can result in a breakout. If the taper provided does not match the requirements, an air gap is
introduced between the mould and the metal shell. As air has the higher resistance to heat in the mould the
heat transfer system, it greatly hampers the formation of the shell of required thickness eventually leading to
breakout.
The loss in taper of the mould caused by wear and distortion leads to a marked increase in the
occurrence of longitudinal corner cracks as a result of re-heating of the corner. As far as the distortion of the
mould is concerned it can take place due to the lower thickness of the copper plate and insufficient support of
the copper plates to take care of the thermal expansion of the copper. Distortion of the mould can also take
place due to damage of the lower part of the mould during dummy bar insertion and excessive taper of the
mould increase the resistance to withdrawal of the mould that results in increased mould wear. The
combination of reverse taper and thermal shrinkage causes air gap thickness to increase the results in
increased wear of the corner thereby lowering the heat extraction which makes the surface to increase. This
phenomenon coupled with the ferro-static pressure induces a tensile strain at the surface in the corner causing
cracks to occur..this crack effectively reduces the thickness of the shell in a highly localised manner, which
may eventually lead to breakout.
Higher the corner radius of the mould , higher would be the air gap. This air gap resists heat transfer
leading to formation of thin shell and facilitated breakout occurrence. In slab or bloom casters , 4 separate
copper plates are fixed to form cavity encircled between them. If there is a gap along the junction between
the 2 copper plates the initial metal penetrates into the gap and gets solidified causing hanging at later stage
to result in formation of a breakout. Also, an impact on heat transfer mechanism influencing occurrence of
break out.
Improper level of metal in the mouldDuring casting metal level in the mould needs to be maintained at
70% - 80% of the mould height .If the molten metal level drops below the Submerged Entry Nozzle, then the
skin formed on the subsequently added metal will be less and break out takes place. This drop in metal level
can take place during nozzle change, tundish change or tundish nozzle choking breakout can occur if the
casting speed is not regulated when there is a restriction of a metal flow from tundish to the mould . Also if
there is any mould overflow caused by improper control of stopper rod leading to running, the over flown
metal sticks to the metal top causing hanging causing difficulty in withdrawal of the strand which after some
time results in break out.
The lowering of the metal level in the mould also causes slag entrapment if the submerged entry
nozzle is closed using the stopper rod for sufficient period of time, the molten metal level in the mould gets
lowered below the allowable limit and if pouring starts again, the liquid metal suppresses the metal slag

resulting in slag entrapment. Also, during the change of the ladle for sequence casting, the tundish metal
level gets down and if proper care is not taken the slag from the tundish can enter the metal inside the mould
through the submerged entry nozzle. Re-oxidation caused by flaring open stream, improper deoxidation, high
slag viscosity envisaged by incorrect aluminium wire injection in the billet mould to result in making the slag
highly viscous due to high Al2O3 can infiltrate in the strand forming slag spots locally inhibiting the shell
formation. This slag entrapment paves way towards improper lubrication between the strand and mould
causing sticking of the mould to the strand resulting in strand discontinuity and leads towards breakout.
Off- centre of the metal stream from tundish to the mouldOff-centre of the casting stream from the
tundish leads to improper heat dissipation causing uneven shell in the mould. Die to the lower strength of the
thin shell, breakout occurs as the metal coming into the mould induces ferrostatic pressure.
Choking of the spray cooling nozzles--the foot roll section is present just below the mould where the water is
directly sprayed on the strand by means of nozzles. The strand supported from all sides by the rollers making
the passage of the strand smoother. Here, maximum amount of the heat is extracted facilitating formation of
thicker skin of the shell. If the nozzles in this section get choked, the skin thickness of the shell will be
comparatively low causing breakout. In case the foot rollers gets jammed, the strand will not pass easily
requiring extra pool by the withdrawal rolls which if crosses a limit causes rupture of the strand surface
leading to breakout.
Dummy bar irregularities Once the molten metal solidifies in the mould above the dummy bar and a shell
of a insufficient thickness is formed, the dummy bar is gradually withdrawn. If the dummy bar is withdrawn
erratically, breakout occurs. Also loose packing of the dummy bar leads to molten metal flow out of the
mould resulting in breakout. If the dummy bar separates out from the strand prior to the lifting of the dummy
bar head, premature separation occurs which can lead to breakout occurrence.
Remedial Measures:-
Considering the impact of breakout on caster utilization and availability, necessary measures are to be
taken to control the occurrence of it:
i. Ensuring uniformity of the temperature by taking temperature only after argon rinsing at the casting platform.
Based on the steel chemistry, cast flow temperature has to be fixed at a superheat of around 6OoC before
placing the ladle on the turret to assure superheat of 25oC -35oC in the tundish.
ii. Control the casting speed based on the temperature monitored in the ladle for a fixed carbon content in the
steel, ensure higher the temperature with lower the casting speed and vice versa. Hence properly adjust the
casting speed depending on the temperature and carbon content of the steel. Increase the casting speed in
steps and maintain steady state casting by casting at a particular speed. For any interruption in casting during
sequencing, reduce the casting speed.
iii. Any casting powder has a self-life period and hence should not be used after the period. Casting powder
should be opened only during casting and can be dried placing a high wattage bulk. Never use the opened
bag of casting powder for another casting. Select the appropriate casting powder for a given steel chemistry.
During start-up of casting , use start-up casting powder of low viscosity and low melting point. In case of a
billet caster ensure, uniform distribution of linseed oil in the mould.
For slab/bloom casters measure the molten slag pool thickness is in excess of 10mm and sufficiently
more than the stroke by using apparatus consisting of steel, copper and aluminium wires attached to a plate.
This can help in avoiding slag entrapment and uniform lubrication of the strand.
iv. Use of multi-tapered moulds in place of conventional linear tapered mould for high speed billet casters.
v. Check the moulds for distortion if any. Select the appropriate mould tapper and adjust it for the narrow face
based on the steel grade and the solidification mode in bloom/slab casters.
vi. Check the water flow in the mould and identify choking if any by measuring the increase in the water
pressure before the start of casting. Overall check the difference in inlet and the outlet water temperature
,pressure and flow coupled with inspection of the flow equipment. Also, check the quality of water. Adjust
the mould cooling patter i.e water flow in lit/ min. for various faces of the mould based on steel grade and
solidification for such grades. To take care of sticking , detect the mould wall temperature changes using
thermocouples and decrease the casting speed so as to allow the shell to re grow uniformly. For a given
caster, ensure that the difference between the inlet and outlet water temperature does not exceed the specific
value during casting.
vii. Ensure corner radius along the copper plates to be 0.2 mm max. If corner gaps exist along the junction of
copper plates , fill the corner gaps with gypsum or lime before start of the caster.
viii. Install Automatic Mould Level Controller in the casters for maintaining the metal level in the mould. For
differentiating the metal and the slag in the mould and take caring of slag entrapment, electromagnetic
sensors can be installed in the mould.
ix. Adjust the tundish nozzles and centre the tundish before casting. Take care of tundish nozzle choking by
assuring CaSi cored wire injection before placement of ladle on the turret for high Al steels to form low
melting calcium aluminates. Stopper running can be avoided by use of freezer.
x. Assure proper de-oxidation, prevent re-oxidation by using tundish metal covering flux and use of shroud
between ladle in the tundish and Mn/Si >3 for billet caster.
xi. Seal the dummy bar head with asbestos rope, use chillers box and ensure proper distribution of chillers
before casting.
xii. Inspect the spray cooling nozzles and water flow through the nozzles for identifying choking if any.
Chocking/Clogging:
In case of continuous casting process sometimes the process is stopped due to occurring of clogging in the
process route. Clogging occurs in three places,
1. Ladle Clogging
2. Tundish Clogging
3. Strand Clogging
1. Ladle Clogging: If the ladle is cooled due to lower preheating, higher rinsing time or higher LCT, then
metal may be solidified in the mould, leading to chocking.
2. Tundish Clogging: if the tundish is not properly preheated or the metal superheat is somewhat lower than
the desired level then chocking may occur in the tundish.
Stopper rod
Choke precipitate
SEN
3. Strand Clogging: The strand may be chocked for not proper preheating or low metal temperature.
Metal
overflow Stopper rod
Strand chocking
SEN

Importance of Clogging:-
Clogging in continuous casting nozzles is the build up of material in the flow passage between the tundish
and mould. The consequences of clogging include:
Decreased productivity. To compensate for clogging, the flow control device (e.g., slide gate) must be further
opened. If the clogging becomes sufficiently severe, the flow control device will no longer be able to compensate and
then either a decrease in casting speed or replacement of the nozzle must result. These events reduce the net casting
throughput and thereby reduce productivity.
Increased cost. Depending on the casting shop, some portions of the clogged nozzles (e.g. submerged entry nozzle)
can be independently replaced during casting. Other clogged portions (e.g., tundish nozzle) can only be replaced by
changing tundishes. Several authors report that nozzle clogging, in lieu of tundish lining lifetime, limits the allowable
tundish lifetime. For example, Hares et al.reported that clogging reduced the number of heats (290 tons) cast from
twelve to six. Therefore nozzle clogging results in additional costs for tundish refurbishment as well as for nozzle
replacement.
Decreased quality. Non-metallic particles can become dislodged from the clog build up and result in unacceptable
cleanliness defects in the product, especially in deep drawn applications requiring oxides be smaller than fifty
microns in diameter. The restriction of the flow passage may also cause undesirable flow patterns in the mould which
thereby cause quality problems (e.g., mould flux ingestion, shell thinning). Also, the mould level transients occurring
when a tundish is replaced due to tundish nozzle clogging, can cause reduced quality.
TYPES OF CLOGS
Tundish nozzle clogging problems take many different forms, and can occur anywhere inside the nozzle,
including the upper well, bore, and ports. They are classified here into four different types according to their
formation mechanism: the transport of oxides present in the steel to the nozzle wall, air aspiration into the nozzle,
chemical reaction between the nozzle refractory and the steel, and steel solidified in the nozzle. In practice, a given
nozzle clog is often a combination of two or more of these types, and its exact cause(s) can be difficult to identify.
1. Transport of oxides present in the steel: The most important cause of nozzle clogging is the deposition of
solid inclusions already present in the steel entering the nozzle. These may arise from many sources:
1.1) deoxidation products from steelmaking and refining processes
1.2) reoxidation products from exposure of the molten steel to air
1.3) slag entrapment
1.4) exogenous inclusions from other sources
1.5) chemical reactions such as the products of inclusion modification
Rackers calculates that a typical clogged nozzle contains 16% of the oxide inclusions that pass through the nozzle.
Thus, it is beneficial both to reduce the number of inclusions, as well as to limit their transport and attachment to the
nozzle walls. The transport of inclusions to the nozzle walls can be lessened by streamlining the flow pattern within
the nozzle to minimize the frequency of contact of inclusions with the walls. In particular, slight misalignment,
separation points in the flow pattern, turbulence, and fluctuations in casting speed are all very detrimental and should
be avoided. Nozzle walls should be smooth to increase the thickness of the laminar boundary layer and discourage
contact. Once oxide particles touch the nozzle wall, they attach due to surface tension forces, and eventually sinter to
form a strong bond. Nozzle wall coatings may help to reduce attachment.
The best way to avoid this source of clogging is to minimize the number of solid inclusions passing through the
nozzle. Inclusions making up a clog would otherwise end up in the final product, where they often have the same
composition and structure.
1.1) Careful refining practices can minimize the quantity of deoxidation products. For example, vacuum degassing
greatly lowers average inclusion levels, relative to conventional argon bubbling. In addition, ladle and tundish slag
composition should be designed to have a low enough oxygen potential to absorb inclusions, while not being so
reactive that steel composition is altered. Late aluminium additions are dangerous because the small inclusions which
form will not have sufficient time to agglomerate and be removed. Luyckx suggests that aluminium should only be
added at tap when the oxygen content is high and the inclusion morphology enables easy flotation. After the last alloy
additions, it is suggested to first stir vigorously for a brief time in order to encourage mixing and collisions for the
inclusions to agglomerate. Argon bubbles are better than electromagnetic stirring because they contribute greatly to
the attachment, agglomeration, and flotation removal of the inclusions. Then, a long period of gentle stirring or
simple natural convection should follow, to allow time for the inclusions transport to the slag or wall surfaces and be
removed. Without enough of this gentle rinse time, further collisions would generate more detrimental large
clusters to be sent into the tundish. Finally, an optimized tundish flow pattern with a basic slag is helpful as the final
refining step prior to entering the tundish nozzle.
1.2) Reoxidation products are caused by the exposure of the molten steel to air. Reoxidation during ladle treatment
can be avoided by providing an adequate slag composition and thickness and then avoiding excessive stirring that
opens up eyes in that slag cover. Reoxidation during steady tundish operation is easy to avoid with a non-porous
slag cover and with ladle nozzles and baffles to avoid excessive surface turbulence. Reoxidation during ladle opening
and tundish filling is a much greater problem that requires great operational care, as discussed elsewhere [2, 10]. In
particular, it is important to use a submerged ladle shroud (preferably bell shaped) throughout, maintain minimal
turbulence during tundish filling, add a tundish slag that quickly forms a continuous liquid layer, use a tight sealing
tundish cover, and even purge the tundish with argon prior to filling.
1.3) Slag entrapment is avoided firstly by minimizing slag carryover. A sensor to consistently detect the presence of
slag is essential in this regard. Care is required during ladle exchanges when slag may become entrapped in the
tundish in several ways, including stream impingement on the slag layer and vortexing. Tundish flow control using
baffles and weirs, a pour box or impact pad is important to give any entrained and emulsified slag a chance to float
out. Finally, it is important to maintain adequate submergence of the tundish nozzle because mould slag can be drawn
into the top of the ports due to the recirculation flow pattern in the upper part of the mould and due to the tendency of
the flux to coat the nozzle. Once it is deposited on the nozzle walls, entrapped slag collects other inclusions, thereby
exacerbating clogging. Clogs caused by slag entrapment are easy to identify by matching the average composition of
the inclusion particles with either the ladle, tundish, or mould slag compositions.
1.4) Exogenous inclusions come from many sources apart from slag entrapment. Loose ceramic material, mortar, and
dirt can be picked up when steel first flows over the refractory surfaces. Ladle packing sand can become entrained in
the flowing steel. Ladle, nozzle, and tundish wall refractory material, and existing oxide deposits can become
dislodged and entrained also. These particles are identifiable from their large size and unusual shapes. Great care
must be given to refractory preparation, assembly, maintenance, and cleanup. Filtration and electromagnetic are also
effective solutions, but are costly and catch only a limited number of particles.
1.5) Chemical reactions generate solid inclusions in many different ways. For example, ladle slags with high FeO or
MnO content often have sufficient oxygen potential to react with aluminium in the steel to form alumina.
This is correlated with increased clogging. Magnesium residuals in the steel, in the aluminium alloy additions, or in
the tundish liner can react to form magnesium aluminate spinels. Titanium reacts to form inclusions which are
particularly prone to clogging, perhaps due to their effect on surface tension. Calcium is often added to avoid
clogging by keeping the inclusions liquefied in the molten steel. Improper calcium treatment can worsen clogging,
however, by producing solid inclusions if the calcia content does not almost match the alumina mass. Too little calcia
causes clogs with calcium-aluminates (eg. CaO6Al2O3), while too much calcium produces calcium sulphides, even
in low S steel. Calcium treatment is best after alumina and especially sulphur have already been minimized. It is also
important to control the slag composition (eg. maintain 2% FeO) and to rinse stir both before and after Ca addition [2].
Finally, it is important to choose refractory compositions which are compatible with the steel, or they may be eroded
to form inclusions.
2. Air aspiration into the nozzle: Air aspiration into the nozzle through cracks and joints leads to reoxidation,
which is an important cause of inclusions and clogging. While regulating the liquid steel flow, the flow control
device creates a local flow restriction which generates a large pressure drop. This venture effect creates a low-
pressure region just below the slide gate or stopper rod. This minimum pressure region can fall below 1 atm (zero
gauge pressure) according to both water model measurements and calculations. This allows air to be drawn into the
nozzle. The rate of air ingress can be huge, approaching that of the steel flow rate for a pressure of 0.30 atm (-30
kPa). The minimum pressure is affected by argon injection, tundish bath depth, casting speed, gate opening, shape of
the surfaces, and clogging, which will be discussed later.
Clogs caused by air aspiration can be identified in several ways. Firstly, if the inclusions are large and dendritic in
structure, this indicates that they formed in a high oxygen environment, such as found near an air leak in the nozzle.
Secondly, an erratic or low argon back pressure during casting likely indicates a crack, leak, or short circuiting
problem that could allow air aspiration. Finally, nitrogen pickup in the steel between the tundish and mould indicates
exposure to air. Rackers calculates that 5ppm nitrogen pickup is accompanied by enough oxygen to clog a typical
nozzle (1-m long and 20-mm thick alumina clog) in seven 250-ton heats. If air enters the nozzle, the oxygen will
react with aluminium in the steel locally to form alumina inclusions. The aspirated oxygen also may create a surface
tension gradient in the steel near the wall. This can generate surprisingly large forces attracting particles towards the
nozzle walls. Rackers calculates that even the small oxygen concentration gradient accompanying a 0.3 ppm nitrogen

pickup could generate surface tension forces that could accelerate a 10 micron inclusion particle to a velocity of 0.9
m/s towards the nozzle wall. This is likely the dominant clogging mechanism in regions of low turbulence and non
recirculating flow. Thus, it is critical to avoid air aspiration. Air aspiration can be addressed through several nozzle
design and operating practices. The nozzle refractory must maintain a stable nonporous barrier that does not allow air
to diffuse through it even after thermal cycling. Use tight tolerances for all nozzle joints. When assembling the
nozzle, smooth and clean all joint surfaces and employ non-cracking, non-porous mortar. Avoid joint movement by
holding the nozzle in place with a strong steel support structure. Check the argon gas line for leaks that might entrain
air and monitor the oxygen content of the argon. Finally, argon gas injection should be optimized, as discussed later
in this article.
3. Chemical reaction between nozzle refractory and steel: Some clogs appear as a uniform film, rather than
a sintered network of particles. These clogs are attributed to reactions between aluminium in the steel and an oxygen
source in the refractory. This oxygen may come from carbon monoxide when carbon in the refractory reacts with
binders and impurities or from silica refractory decomposition. Controlling refractory composition (eg. Avoid Na, K,
and Si impurities) or coating the nozzle walls with various materials, such as pure alumina or BN may help to prevent
this and other clogging mechanisms. Controlling chemical reactions at the refractory / steel interface has also been
suggested as a countermeasure to clogging. Incorporating calcia into the nozzle refractory may prevent clogging by
liquifying alumina inclusions at the wall, so long as CaO diffusion to the interface is fast enough and nozzle erosion
is not a problem.
4. Steel solidified in the nozzle: Although heat losses from the nozzle refractories are very small, steel may
freeze within the nozzle either at the start of cast, if the nozzle preheat is inadequate, or within a clog matrix, where
the flow rate is very slow. These problems are more likely if the steel superheat is very low, or the alloy freezing
range is very large. Freezing occurs initially because the preheated nozzle wall temperature is significantly below the
steel solidus. The nozzle walls heat up within a few minutes to melt this layer away, however, but clogging may start
if another mechanism is triggered.
Clog networks can grow more easily when they are supported by a matrix of solidified steel. Some clogs consist
solely of dense concentrations of oxides, as surface tension rejects steel from inner spaces. Other clogs consist of a
network of small oxide particles which contain steel, especially for high carbon steels. These clogs appear to form by
first collecting and sintering together a network of oxides against the nozzle wall. After an initial clog layer of 3-12
mm thick has built up, the liquid steel trapped within it flows so slowly that it may start to solidify (depending on the
flow and thermal conditions). This strengthens the otherwise weak inclusion network and allows it grow further into
the liquid, filtering inclusions from the steel flowing through it as it grows. Only the innermost 3-12 mm of the
inclusion network must be strong enough to withstand the drag of the turbulent steel flowing through it. As the
roughness of the clog surface increases, the probability of intercepting and entraining particles increases and clogging
may accelerate.

1. Casting Temperature: Lower casting temperature than the desired level is the main reasons for
chocking.
2. LCT: Higher Ladle Cycling time is also responsible for chocking. ( Data Table. 5)
3. Delays due to mechanical purposes also provide a cause for chocking.
4. Aluminium is added to deoxidise the steel, excess aluminium remains in the steel. If the aluminium
content in the steel is less than 0.02% it is harmless. Otherwise it is detrimental to the properties of steel.
And it leads to nozzle chocking. ( Data Table. 6)
5. Aluminium is added to deoxidise the steel, excess aluminium remains in the steel. If the aluminium
content in the steel is less than 0.02% it is harmless. Otherwise it is detrimental to the properties of steel.
And it leads to nozzle chocking.
6. Transport of Deoxidation Products to the Nozzle Wall: Several theories have been proposed
concerning flow patterns and geometries which enhance transport of deoxidation products to the nozzle
wall.
Turbulent Recirculation Zones: Within a recirculation zone, turbulent velocity fluctuations oriented
in all directions are present. Those fluctuations toward the wall will enable deposition.
Turbulent Flow: Turbulent eddies, even in the absence of a recirculation zone, will transport
deoxidation products to the nozzle wall.
Rough Nozzle Walls: As the roughness of the nozzle wall is increased (e.g., due to irregular buildup or
erosion) the probability of interception of entrained deoxidation particles increases.
External Corners: Since the density of alumina is less than steel, alumina will tend to be driven
toward the wall for flow around an external corner (e.g., tundish nozzle entry). This driving force is
expected to be significant only for large alumina particles (e.g., 36 micron).
7. Attachment of Deoxidation Products to the Nozzle Wall: Deoxidation particles are attached to the
nozzle wall by surface tension and, after sufficient time, by sintered bonds. The surface tension of the
steel creates a void and, consequently, an attractive force between the deoxidation product and the wall
(or another deoxidation product). The magnitude of this force for the case of a 2.5 micron deoxidation
product attaching to a ceramic filter has been calculated to be approximately an order of magnitude
greater than the drag and buoyant forces on the particle. The sintered bond between the particle and wall
(or another particle) forms relatively rapidly at these temperatures (e.g., only 0.03 seconds is required for
two ten micron particles to develop a sufficient neck between them to withstand drag and buoyant
forces).
Remedial Measures:-
A method for reducing tundish and ladle nozzle clogging in a steel making process by introducing an
additive into molten steel containers used in steel making at predetermined times. The additives introduced are oxides
of iron which contain between 10% and 30% of oxygen by weight. By adding the oxides of iron in a controlled
manner using a cored wire apparatus, clogs in tundish or ladle nozzles in the steel making process are avoided and
the steel flows more smoothly with less interruptions due to clogged nozzles. A preferred embodiment uses oxides of
iron contained in a cored wire which can be introduced at a predetermined rate and readily mix with molten steel,
provide better distribution of dissolved oxygen in the steel to oxidize inclusions, and facilitate removal of the
inclusions before the inclusions can cause nozzle clogging.
The most obvious means to reduce clogging is to decrease the concentration of deoxidation products and the
formation of reoxidation products. Means to achieve this increase in steel cleanliness have been reviewed by Byrne et
al. and Szekeres. The important aspects of clean steelmaking include:
Ladle Refining Practice: A vacuum degassing treatment yields better cleanliness than argon bubbling.
Reoxidation Prevention: Submerged ladle-to-tundish pouring, shielded tundish surface and leak-tight refractory
joints will reduce exposure of the steel to oxygen and thereby improve cleanliness.
Deoxidation Product Removal: Optimal tundish flow patterns as well as filtration and electromagnetic techniques
can remove deoxidation products from the melt.
Flux Entrainment Prevention. Submerged ladle: To-tundish pouring and avoidance of ladle slag carryover will
reduce the amount of exogenous inclusions in the melt.
It is unlikely that steel cleanliness improvements will completely eliminate nozzle clogging.

Dawson calculated that for typical casting conditions, nozzle blockage could occur if as little as one in every 1500
non-metallic inclusions were deposited on the nozzle. To reduce the deposition of the entrained deoxidation products,
several techniques have been utilized as discussed below.
1. Argon Injection: Argon injected through the nozzle wall or stopper rod into the steel stream is widely
employed to reduce nozzle clogging. A typical injection rate is 5 five litre/minute. Several reasons have been
suggested for the improved clogging resistance:
A film of argon is formed on the nozzle wall which prevents the deoxidation product from contacting the
wall .
The argon bubbles flush the deoxidation products off the nozzle.
The argon bubbles promote the flotation of deoxidation products.
Argon injection increases the turbulence and thereby causes the deposit to be flushed off. It is noted that this
mechanism contradicts a previously mentioned hypothesis which states that turbulence enhances deposition.
The pressure inside the nozzle is increased which thereby reduces air aspiration through the nozzle. In the
absence of argon injection, negative gauge pressure has been measured in water models near the slide gate and the
stopper rod seating surface.
The argon prevents a chemical reaction between the steel and the refractory. The argon can be injected
through the pores in the refractory material or via machined or laser cut holes in the refractory. Tailoring the argon
flow to be greater in areas of high deposition [18, 44] and to be locally uniform has been shown to reduce clogging.
Disadvantages of argon injection include increased quality defects and nozzle slag line erosion due to the increased
mould level fluctuations, bubble entrapment by the shell , and nozzle cracking due to high back pressure or decreased
nozzle thermal shock resistance. It is also suspected that argon injection tends to move the clogging problem to a
different location.
2. Calcium Treatment: Alumina clogging can be reduced by adding calcium to the steel to prevent the
formation of solid alumina. For a typical melt temperature of 1550 C, liquid is the equilibrium phase for calcia-
alumina mixtures containing 40 - 60% alumina. Furthermore, it is believed that under steelmaking conditions,
mixtures containing a higher fraction of alumina will be also be liquid. This is based on the observation that when
CaO2Al2O3 inclusions (79% alumina) are found in the final cast product, these inclusions take a spherical form and
the nozzle experiences much less clogging. The disadvantages of calcium treatment include:
Increased clogging relative to the non-treated condition if insufficient calcium is added, due to the formation
of CaO6Al2O3.
Erosion of refractories. Also, calcium treatment will not work for high sulphur steels because calcium will
react with sulphur to form solid calcium sulphide instead of liquefying the alumina (e.g., sulphur must be less than
0.007% for a typical total aluminium concentration of 0.04%). However, it has been proposed that
Calcium treatment might still be successful if the sulphur is added after calcium treatment.
3. Nozzle Material Modifications: A variety of nozzle compositions have been investigated. Calcia additions
to the nozzle have yielded decreased clogging by liquefying the inclusions, as discussed above. The effectiveness of
this method is limited by the diffusion of the calcia to the refractory surface. Other compositions and coatings have
also been attempted, but the cause for the decreased clogging is uncertain. For example, the addition of boron nitride
has been shown to markedly reduce clogging. However, it is not known whether the beneficial effect of boron nitride
is due to the formation of a liquid boron oxide film, decreased surface roughness, or another cause. Other possible
explanations for the observed clogging reduction of the various materials investigated are decreased thermal
conductivity, decreased contact angle with steel, reduced reactivity with steel, and decreased air aspiration.
4. Nozzle Geometry Modifications: In an effort to reduce the effect of clogging, oversized nozzle bores and
replaceable submerged entry nozzles are widely employed. To reduce the degree of clogging, the following have
been investigated:
Improved joint sealing. Strengthening the steelwork that holds the nozzle in place was found to reduce air
aspiration and thereby reduce clogging.
Rounded nozzle entrance. Incorporating a rounded entrance (in lieu of a sharp corner) to the tundish nozzle
and ensuring proper vertical alignment can reduce clogging at the nozzle entrance by eliminating separated flow.
Internal step. A five millimetre annular step incorporated at the mid-height of the submerged entry nozzle has
been found to decrease alumina buildup in the lower part of the nozzle as well as decreasing flow impingement on
the mould wide face.
Varying nozzle internal diameter. Increasing the nozzle internal diameter just below the stopper rod seating
surface has reduced clogging.
Flat bottomed nozzle. Decreased port clogging was observed when the elevation of the nozzle internal
bottom and port bottom were coincident (i.e., no nozzle well).
Insulation around nozzle. Insulation, as well as preheat and heating, around the clogging location
may reduce clogging.
5. A method for reducing tundish and ladle nozzle clogging in a steel making process comprising: (a) providing
a means for introducing an additive into molten steel in a container used in steel making; (b) providing that said

additive is a mixture containing oxides of iron; (c) adding said additive to molten steel in a predetermined amount for
each kilogram of molten steel in said container.
6. A method for reducing tundish and ladle nozzle clogging in a steel making process of claim 5 further
comprising that providing said additive is a mixture containing FeO, Fe3O4, and Fe2O.
7. A method for reducing tundish and ladle nozzle clogging in a steel making process of claim 6 wherein said
step of adding said additive in a predetermined amount for kilogram of molten steel further comprises that step of
adding said additive in a predetermined amount shall add O2 to said molten steel at an amount no less than one part
per million to no more than 1,000 parts per million.
8. A method for reducing tundish and ladle nozzle clogging in a steel making process of claim 3 wherein said
step of adding said additive in a predetermined amount for each kilogram of molten steel comprises that
predetermined amount shall range from at least 0.00333 kilograms per metric ton of molten steel to no more than 10
kilograms per metric ton of molten steel.

Observation tables for tha past few years:

Calculation of the three abnormalities occurring in the last few years:
2011 2012 2013

Running Tendency 8.54% 7.8% 6.5%
Choking 16.46% 16.25% 26.3%
Breakout 20.32% 7.3% 7.89%

Few Case Studies :-
Data Table. 1
DATE: 28.05.2013
Heat No. Machine Tundish Rinse Ar. Tundish Ladle Cycle No. of Casting
No. No./Life (min) Superheat Steel comp. Time(hour) working Speed
(C) (Si/Al) Strands (m/min)
110/1 8 145 0.16/0.040
110/2 20 85 0.15/0.049
303420 4 110/3 12 104 0.19/0.032 4
110/4 8 114 0.20/0.042
110/5 12 97 0.16/0.029
Note: Here Si/Al % is appropriate, but 1st Ar. Superheat is 145C whereas that must be around 100C. And the
sequence temperatures must be around 80C, not more than that. For all these running occurs.
Data Table. 2
DATE: 11.05.2013
Heat No. Machine Tundish Rinse Ar Tundish Ladle Cycle No. of Casting
No. No./Life (min) Superheat Steel comp. Time(hour) working Speed
302305 3 8 0.04/0.019 4
Note: Si % is very much lower than the desired level, resulting running.
Data Table. 3
DATE: 27.05.2013
No. No./Life (min) Superheat Steel comp. Time working Speed
2 hour
303373A 2 15 68 0.19/0.14 30mins 4
Note: LCT is very high (must be around 1hour 15 mins), but still the temperature is also kept low (68C). The
temperature should be around 85C. And the Al % is also very high, helping to form precipitate. Running happens as
a result.

Data Table. 4
DATE: 27.05.2013
0.8 to
303398 1 3 0.95
Note: Speed is very much higher than the desired level, resulting Breakout.
Data Table. 5
DATE: 26.05.2013
303329 2 8 96 7 hour 3
Note: LCT time is very much higher than the desired time level (1 hour 15 mins). Due to that tundish temperature is
very low during working. Initial Tundish Temperature is 10C and the final one is 5C. All the causes stated above
results in chocking.
Data Table. 6
DATE: 20.05.2013
1 hour
302910 2 6 76 12mins 3
Note: As it is a 3 strand machine higher temperature is required than that was given. And the rinsing is also lower
causing no homogenization in the melt. Due to these the initial tundish superheat is around 16C and the final one
is around 3C. And all these happen without any delay in ladle cycle, showing the importance of previous causes.
Total recycled metal from there was 82 tons.

Bibliography
Steel Making A. K .Chakrabarty
An Introduction to Modern Steel Making Dr. R. H. Tupkary & V. R. Tupkary
Break outs in Continuous Casting of steel B. V. R. Raja
Clogging in Continuous Casting Nozzles - K. G. Rackers and B. G. Thomas
Solidification control in continuous casting of steel - S Mazumdar and S K Ray

Abnormalities in Continuous Casting

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Abnormalities in Continuous Casting

Uploaded by

Copyright:

Available Formats

Abnormalities in Continuous Casting

A project report by:

Rupam Mandal 2920

Deshik Sarkar 2926 Bengal Engineering and Science University,

Abnormalities in Continuous Casting | 1

Contents Page No.

Lay out of Visakhapatnam Steel Plant ------------------------------------- 4

An Overview of VSP ------------------------------------- 5

Raw Material Handling Plant(RHMP) ------------------------------------- 7

General Overview of Steel Melt Shop ------------------------------------- 12

Description Of the Facilities ------------------------------------- 13

Mixer Shop ------------------------------------- 13

Facilities and Equipment-Lift and Turn stand ------------------------------------- 17

Abnormalities in Continuous Casting | 2

Bloom Storage Yard ------------------------------------- 18

Principles of Continuous Casting Process ------------------------------------- 19

The Continuous Casting Machine ------------------------------------- 20

Different Types of Machine ------------------------------------- 21

General Features of Continuous Casting Machine at VSP------------------------------------- 23

Casting Powder ------------------------------------- 25

Abnormalities in Continuous Casting Section ------------------------------------- 26

Running Tendency ------------------------------------- 26

Few Case Studies ------------------------------------- 55

Abnormalities in Continuous Casting | 3

VSP Technology : State-of-the-Art

7 meter tall Coke Oven Batteries with coke dry quenching

Major Sources of Raw Materials

Raw Material Source

Abnormalities in Continuous Casting | 6

VSP annually requires quality raw materials

Coke ovens & Coal Chemical Plant (Co&CCP)

Sinter Plant (SP)

Hot Sinter discharged from Sintering

Blast Furnaces (BF)

Hot Metal is produced in Blast

Steel Melting Shop (SMS)

Abnormalities in Continuous Casting | 8

Characteristics of VSP Convertors :

Capacity - 150 Tones per heat/blow

Continuous casting Department (CCD)

Blooms produced in SMS-CCD do not find

Abnormalities in Continuous Casting | 9

Medium Merchant & Structural Mill (MMSM)

Wire Rod Mill (WRM)

Abnormalities in Continuous Casting | 10

Abnormalities in Continuous Casting | 11

General overview of Steel Melt Shop:-

Ladle Secondary Gas Bloom

Tundish ARS &

Abnormalities in Continuous Casting | 12

Each of these has further facilities:

Continuous Casting Shop :

DESCRIPTION OF THE FACILITIES

Abnormalities in Continuous Casting | 13

Temperature Range: 1250-1425 oC.

Bulk Material Handling Section(BMHS)

BULK MATERIAL CaO +MgO LOI(Loss of Ignition) SiO2 Size

CONTENT Fe SiO2 Al2O3 MnO2

Size -15 60 mm.

Requirement =0.5-3 T as per blowing conditions.

Raw or calcined Dolo= Used to increase Lining life of converter.

Abnormalities in Continuous Casting | 14