Continuous Casting Machine

Types Of Continuous Casting Machine

ELECTRICS AND AUTOMATION FOR CONTINUOUS CASTING

Sophisticated automation packages are prerequisite for state-of-the-art quality steelmaking. India Power Melt has always been a driver of innovation in this area, especially also providing expert technological packages and models that cover all aspects of the continuous casting process.

This capability is impressively demonstrated by recent advancements in automation solutions from India Power Melt that include: Dyna Phase, Dynacs 3D, and Dyna Gap Soft Reduction 3D. This state-of-the-art suite of dynamic secondary cooling and soft-reduction packages take into account thermodynamic effects such as shrinkage and phase transitions, and thereby significantly contribute to direct quality improvements during the solidification phase in the continuous casting process.

The Mold Expert breakout predetection system increases plant availability and decreases maintenance time by prompt alarming. Thanks to its superior performance the Mold Expert system has become the world’s leading system for mold monitoring, with close to 200 installations worldwide. In addition to breakout prevention, Mold Expert provides an ever increasing number of expert packages that are used to detect possible surface defects and inform operators about challenging casting conditions.

The well proven LevCon mold level control package adapts reliably and extremely quickly to mold level fluctuations and changing casting conditions. This is made possible by advanced model-based control algorithms that can actually look into the near future to avoid disturbances in the control loop. Unsteady bulging is actively suppressed by a powerful algorithm based on modern control theory. The intelligent interaction between the advanced software and highly robust mechanical components improves safety and brings plant operators one step closer to fully automatic casting operation.

Further highlighted technological packages and process experts

Dyna Width: Width adjustment with highest accuracy and fast speed
Quality Expert: a milestone in improved quality supervision, quality prediction and control
Yield Expert: cut length/weight optimization for minimized scrap and optimized yield
Intermix Expert: precisely determination of the mixing area of two different grades on the strand
Nozzle Expert: highest accuracy in detecting clogged nozzles and broken hoses
Speed Expert: optimal casting speed for increased throughput and improved quality
Dyna Flex: hydraulic Oscillator for perfect surface quality

TECHNOLOGY AND MODERNIZATION PACKAGES

Get Striking Results With Incremental Investment

Name	Short Description
Mold Checker	3D measurement for the inner shape of continuous casting molds
Automatic Thermocouple Checker	Automatic sensor test for breakout prediction system for continuous casting
LiquiRob for Casting	Robotic solution for continuous casting machines
Mold Expert Fiber	Live view into caster mold based on fiber optic technology
Automatic Segment Checker	Verification of casting segment condition in maintenance
OPAL	Optical measurement for alignment of segment rolls in caster.
Powder Expert	Feeder with high precision powder control in the caster mold
DynaFlex	Hydraulic mold oscillator for continuous casting
DynaWidth	Dynamic mold width adjustment for continuous slab casters
Mold Expert	Breakout pre-detection and mold monitoring
CC Optimizer	Process optimization (Level 2) for continuous casting
Single Roll DynaGap (SRD) Segment	Dynamic alignment of individual roll gap for change of steel grade, cooling, superheating, and casting speed
Lance Checker	Test and diagnosis system for liquid iron and steel measuring devices
OsciChecker	Portable device for mold oscillation measurement in continuous casting machines
OsciMon	Online monitoring of mold oscillation in continuous casting machines
LevCon	Mold-level control with highest precision for continuous casting
DynaJet Flex	Pulse-width modulated cooling for exact cooling of slab edges
Smart Mold	High-performance cassette-type mold
Smart Bender and Smart Segments	Precise support and guiding of strand during solidification
Star Rollers	Different roller types to meet all needs of ideal intermediate support
DynaTac	High-temperature casting package for reduced or no-spray cooling.
Taper Checker	Measurement for taper adjustment for slab casters
Torch Cutting Machine	Fully integrated and optimized torch cutting solution
Scrap Torch Cutting Machine	Environmentally clean scrap processing

CONTINUOUS CASTING MACHINES

Revolutionizing Steel Production

In the dynamic world of modern manufacturing, the Continuous Casting Machine (CCM) has emerged as a game-changer, revolutionizing the way steel is produced and shaping the future of various industries. As a leading provider of advanced manufacturing solutions, India Powermelt Pvt.Ltd. has been at the forefront of this technological revolution, offering cutting-edge Continuous Casting Machines that are transforming the steel industry.

Understanding Continuous Casting

Continuous Casting is a process where molten steel is solidified into a “semi-finished” billet, bloom, or slab for subsequent rolling in finishing mills. This process has evolved significantly since its introduction in the 1950s, offering improved yield, quality, productivity, and cost-efficiency compared to traditional ingot casting methods. The Continuous Casting Machine plays a crucial role in this process, allowing for the precise control and automation of the casting operation. These machines are designed to handle a wide range of steel grades, from carbon and stainless steel to specialty alloys, ensuring that the final product meets the highest quality standards.

Continuous Casting Process Details

Molten metal from an induction furnace is fed directly into a mold with the required shape.

(1). The molten metal enters the die through a series of holes in the upper portion of the mold. Heat is extracted by the water-cooled jacket surrounding the mold, and the metal solidifies. The molten metal above the die acts as a riser keeping the die filled and preventing the formation of shrinkage cavities in the required finished form: bar, tube or special shape.

(2).Solidification occurs in the die and then the solidified metal casting exits through the bottom of the die by means of a continuous process of short intermittent extractions performed by a mechanical device.

(3).The product is withdrawn at controlled increments and speed until the production length is met.

(4). Lengths are cut off by a traveling saw which moves with the cast shape. The standard length for continuous cast material is 144 inches.

(5).Since continuous casting operates as a true gravity fed bottom-flow casting method, the process minimizes the possible trapping of casual dirt and dross in the casting. Foreign matter in the furnace crucible floats to the top of the melt so it does not become part of the cast product.

Low casting temperatures combined with the chill mold and directional solidification inherent in this process promote a homogeneous, fine-grained, high-density product with high yield.

A horizontal method of continuous casting has also found some favor in the foundry industry. The principle is basically the same as it is for the vertical method, except the equipment stretches out horizontally and is contained on one level. Tube hollows produced by the horizontal method require somewhat more stock allowance to compensate for the natural effect of gravity on ovality and straightness.