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Feasibility Study of Continuous Casting of Steel Billets in Twin-Belt Caster

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Abstract

Integrated casting and rolling in a series production line is well established for the non-ferrous metals through the use of twin-belt casting technology. However, this twin-belt casting with high mass flow is not yet commercialized in the continuous production of steel alloys. A novel steel casting for the in-line rolling (named LUUP method) is presented and one main focus of this work is to design a casting machine: twin-belt caster. Influence of mass flow rate and dimensional ratio on the solidification, compensation, and total process length is addressed. A gap-dependent belt and dam block side heat transfer is modeled. The admissible casting speed due to the limitations of caster length and shell strength is addressed. The total process length only depends on the mass flow rate. A 2D traveling slice numerical model is presented with realistic boundary conditions for the entire process starting from the meniscus to roll mill entry.

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Notes

  1. Contirod\(^{\tiny {\textregistered }}\) is a registered trademark of Aurubis, Belgium.

Abbreviations

T :

Temperature (\(^{\circ }{\rm C}\))

\(\lambda \) :

Thermal conductivity (W/mK)

c :

Specific heat (J/kg K)

\(\rho \) :

Density (\({\rm kg}/{\rm m}^3\))

a :

Thermal diffusivity (\({\rm m}^2/{\rm s}\))

\(\Delta h\) :

Latent heat (kJ/kg)

\(\delta \) :

Thickness (m)

h :

Heat transfer coefficient (\({\rm W}/{\rm m}^2{\rm K}\))

\(\dot{m}\) :

Mass flow rate (kg/s)

\(\theta =\frac{T-T_{\rm su}}{T_{\rm in}-T_{\rm su}}\) :

Dimensionless temperature

\(\Delta =\frac{\delta }{s/2}\) :

Dimensionless solid thickness

B :

Billet width (m)

s :

Billet thickness (m)

\(V_{\rm c}\) :

Casting speed (m/min)

\({\rm Ste}=\frac{c(T_{\rm in}-T_{\rm su})}{\Delta h}\) :

Stefan number

\(Fo=\frac{at}{(s/2)^2}\) :

Fourier number

\(X=\frac{x}{s/2}\) :

Dimensionless coordinate

in:

Initial

int:

Interface between belt and shell

s:

Solidus

l:

Liquidus

bin:

Belt side contact with liquid metal

bout:

Belt side contact with water

w:

Dam block side shell

m:

Dam block

\({\infty }\) :

Ambient

c:

Coating

sh:

Shell

b:

Belt

a:

Air

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Acknowledgments

The financial support provided by the German Science Foundation (DFG) through graduate school GRK 1554 is sincerely acknowledged.

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Authors and Affiliations

  1. Birla Institute of Technology and Science - Pilani, Hyderabad Campus, Jawahar Nagar, Shameerpet Mandal, Hyderabad, 500078, India

    Pavan Kumar Penumakala

  2. Department of Mechanical Engineering, National Institute of Technology, Tiruchirappalli, 620 015, India

    Ashok Kumar Nallathambi

  3. Otto von Guericke University Magdeburg, Universitaetsplatz 2, 39106, Magdeburg, Germany

    Eckehard Specht

  4. Urlau Innomanagement GmbH, Oberhusrain 47, 6010, Kriens, Switzerland

    Ulrich Urlau

  5. Hazelett Corporation, PO Box 600, 135 West Lakeshore Drive, Colchester, VT, 05446, USA

    Doug Hamilton & Charlie Dykes

Authors
  1. Pavan Kumar Penumakala
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  2. Ashok Kumar Nallathambi
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  3. Eckehard Specht
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  4. Ulrich Urlau
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  5. Doug Hamilton
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  6. Charlie Dykes
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Corresponding author

Correspondence to Ashok Kumar Nallathambi.

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Manuscript submitted December 1, 2017.

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Penumakala, P.K., Nallathambi, A.K., Specht, E. et al. Feasibility Study of Continuous Casting of Steel Billets in Twin-Belt Caster. Metall Mater Trans B 50, 42–51 (2019). https://doi.org/10.1007/s11663-018-1430-5

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  • DOI: https://doi.org/10.1007/s11663-018-1430-5

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